Grid frame structure

Abstract

A grid frame structure (80) for supporting one or more robotic loading handling devices operating on the grid frame structure, the grid frame structure comprises: i) a support frame structure (82) comprising a plurality of prefabricated frameworks (86a, 86b) configured to be arranged in a three-dimensional grid pattern, the three-dimensional grid pattern comprising a plurality of modular storage units (96) for storing stacks of a plurality of containers, the plurality of modular storage units (86a, 86b) are arranged such that adjacent modular storage units are configured to share a common prefabricated framework (126), each of the plurality of prefabricated frameworks (86a, 86b) being located in a vertical plane and comprising a plurality of vertical members (88) reinforced by reinforcing members (90); ii) a track system for guiding movement of one or more robotic load handling devices on the grid frame structure, the track system configured to be mounted to the support frame structure and comprising a plurality of tracks arranged in a grid pattern comprising a plurality of grid cells, a plurality of modular memory cells and extending across the plurality of modular memory cells such that each modular memory cell of the plurality of modular memory cells is configured to support a subset of two or more grid cells of the track system; wherein the track system further comprises a track support structure (82) comprising a plurality of track supports arranged in a grid pattern corresponding to the grid pattern of the track system, the track support structure being subdivided into a plurality of modular sub-frameworks (140, 142, 144), the plurality of modular sub-frameworks (140, 142, 144) are arranged such that each of the plurality of modular sub-frameworks comprises a sub-group of two or more grid cells of the track system, and wherein the plurality of modular sub-frameworks (140, 142, 144) are configured to be connected to each other by one or more sliding joints at junctions between adjacent modular storage cells, adjacent modular sub-frameworks are movable relative to each other along a substantially horizontal plane by one or more sliding joints.

Description

Technical Field

[0001] The present invention relates to the field of remotely operated load handling equipment located on tracks on a grid frame structure, which is used to handle storage containers or boxes stacked in the grid frame structure, and more particularly to a grid frame structure for supporting the remotely operated load handling equipment. Background Art

[0002] As is well known, storage and retrieval systems 1 comprise a three-dimensional storage grid frame structure in which storage containers / bins / boxes are stacked on top of each other. PCT (Ocado) Publication No. WO2015 / 185628A describes a known storage and fulfillment or distribution system in which stacks of bins or containers are arranged within the grid frame structure. Access to the bins or containers is provided by remotely operated load handling equipment located on rails atop the grid frame structure. Figures 1 to 3 of the accompanying drawings schematically illustrate this type of system.

[0003] As shown in Figures 1 and 2, stackable containers, called storage bins or containers 10, are stacked on top of each other to form a stack 12. The stack 12 is arranged in a grid frame structure 14 of a warehouse or production environment. The grid frame structure is composed of a plurality of storage columns or grid columns. Figure 1 is a schematic perspective view of the grid frame structure 14, and Figure 2 is a top view showing the stack 12 of bins 10 arranged within the grid frame structure 14. Each bin 10 typically holds a plurality of product items (not shown), and the product items within the bins 10 can be the same or can be different product types, depending on the application.

[0004] Specifically, the grid frame structure 14 includes a plurality of vertical columns or upright members or upright posts 16 that support horizontal grid members 18, 20. A first set of parallel horizontal grid members 18 are arranged perpendicular to a second set of parallel horizontal grid members 20 to form a track system or grid structure or grid 15 comprising a plurality of grid cells 17. Each grid cell in the grid frame structure has at least one grid column for stacking storage containers. For the avoidance of doubt, the term "grid frame structure" is used to refer to a three-dimensional structure in which storage containers are stored, and the terms "track system," "grid structure," and "grid" are used interchangeably to refer to a two-dimensional structure in a substantially horizontal plane on which load handling equipment operates. The grid cells have openings to allow load handling equipment to lift containers or storage bins through the grid cells. In the track system, the first set of parallel horizontal grid members 18 intersect the second set of parallel horizontal grid members at nodes. The track system is supported by upright members 16 at each node, or point where the grid members intersect, such that the upright members are interconnected at their top ends by intersecting grid members. The grid members 16, 18, 20 are typically fabricated from metal and are typically welded or bolted together or a combination of welds and bolts. Storage bins or containers 10 are stacked between the upright members 16 of the grid frame structure 14 such that the upright members 16 prevent horizontal movement of the stack 12 of bins 10 and guide vertical movement of the storage bins 10.

[0005] The top layer of the grid frame structure 14 includes rails or tracks 22 arranged in a grid pattern atop the stack 12 to define a track system. Also referring to FIG3 , the rails 22 support a plurality of load handling devices 30. The track system includes a first set 22 a of parallel rails 22 to guide movement of the robotic load handling devices 30 atop the grid frame structure 14 in a first direction (e.g., the X direction), and a second set 22 b of parallel rails 22 arranged perpendicular to the first set 22 a to guide movement of the load handling devices 30 in a second direction (e.g., the Y direction) perpendicular to the first direction. In this manner, the rails 22 allow the robotic load handling devices 30 to move laterally in two dimensions in a horizontal XY plane, allowing the load handling devices 30 to be moved to any position above the stack 12. For purposes of defining the present invention, the terms "robotic" load handling device and load handling device are used interchangeably in this specification to refer to the same device.

[0006] The rails or tracks can be separate components from the grid members (sometimes referred to as "track supports"), or alternatively, the rails can be integrated into the grid members as a single body, i.e., form part of the grid members. For example, each of the first and second sets of horizontal grid members 18, 20 of the track system can serve as a track support structure, and the first and second sets of rails of the track system can be mounted to the track support structure for guiding load handling equipment in a two-dimensional manner on the track system.

[0007] PCT Patent Publication No. WO2015 / 019055 (Ocado), incorporated herein by reference, describes a known load handling device (also known as a robot) 30, shown in Figures 4 and 5 , comprising a carrier body 32. Each load handling device 30 covers only a single grid space or grid cell of the grid frame structure 14. Here, the load handling device 30 includes a wheel assembly comprising a first set of wheels 34, comprising a pair of wheels at the front of the carrier body 32 and a pair of wheels 34 at the rear of the carrier 32, for engaging with a first set of rails or tracks to guide movement of the device in a first direction, and a second set of wheels 36, comprising a pair of wheels 36 on each side of the carrier 32, for engaging with a second set of rails or tracks to guide movement of the device in a second direction. Each set of wheels is driven to enable movement of the carrier along the tracks in the X and Y directions, respectively. One or both sets of wheels can be moved vertically to lift each set of wheels off its respective track, thereby allowing the vehicle to move in a desired direction (eg, X or Y) on the track system.

[0008] The load handling equipment 30 is equipped with a lifting device or crane mechanism for lifting storage containers from above. The crane mechanism includes a winch tether or cable 38 wound on a reel or spool (not shown), and a gripping device 39 in the form of a lifting frame. The lifting device includes a set of lifting tethers 38 extending vertically and connected near or at the four corners of a lifting frame 39 (also known as a gripping device) (one tether near each corner of the gripping device) for releasable connection to the storage container 10. The gripping device 39 is configured to releasably grip the top of the storage container 10 to lift it from a stack of containers in a storage system of the type shown in Figures 1 and 2.

[0009] Wheels 34, 36 are arranged around the periphery of a cavity or recess (also referred to as a container-receiving recess or container-receiving space) 40 in the lower portion. As shown in Figures 5(a) and 5(b), the recess is sized to accommodate the container 10 when it is lifted by the lifting mechanism. While in the recess, the container is lifted off the underlying rails, enabling the carrier to be moved laterally to different locations. Once at its target location, such as another stack, an access point in a storage system, or a conveyor belt, the box or container can be lowered from the container-receiving portion and released from the gripping device. The container-receiving space can include a cavity or recess disposed within the carrier body, such as that described in WO2015 / 019055 (Ocado Innovation Limited). Alternatively, the carrier body of the load handling device can include a cantilever as taught in WO2019 / 238702 (Autostore Technology AS), in which case the container-receiving space is located below the cantilever of the load handling device. In this case, the gripping device is lifted by the cantilever so that it can engage and lift the container from the stack into the container-receiving space below the cantilever.

[0010] To ensure the stability of the grid frame structure, prior art storage systems rely heavily on various supports and reinforcements arranged within the grid frame structure or at least partially along the periphery of the grid frame structure. However, the use of various supports and reinforcements (anti-movement reinforcements) to stabilize the grid frame structure from internal and external forces is disadvantageous for a number of reasons. The grid frame structure occupies space or area that could be used to store containers, and therefore, it hinders the optimal utilization of the available space or area for storing containers. The need for support structures may limit the available options for positioning the grid frame structure because any auxiliary grid support structures will generally need to be connected to surrounding structures, such as the interior walls of a building. The need for support structures to stabilize the grid frame structure is generally not cost-effective and takes up useful storage space.

[0011] WO2019 / 101367 (Autostore Technology AS) teaches a self-supporting storage grid that requires less auxiliary grid support structure by integrating the grid support structure into the storage grid structure. The grid support structure consists of four storage columns interconnected by a plurality of vertically inclined support struts. The storage column profile has a cross-section comprising a hollow center portion and four corner portions, each corner portion comprising two vertical box guides for accommodating the corners of a storage box. The support struts are of a width that allows them to fit between the two parallel guides without compromising the storage column's ability to accommodate stacks of containers or storage boxes.

[0012] Prior art grid frame structures are constructed by individually positioning a plurality of vertical columns in a grid-like pattern on the ground. Assemblies in which individual vertical columns are assembled one by one are sometimes referred to as "stick-built" structures. This "stick-built" method of assembling grid frame structures requires extensive and time-consuming adjustments to ensure reliable operation of robotic load handling equipment on the track. The height of the vertical columns, and therefore the levelness of the grid mounted thereon, is adjusted by one or more adjustable feet at the base or bottom end of each vertical column. Subgroups of vertical columns are reinforced together to provide structural stability to the grid frame structure. The vertical columns are interconnected at their top ends by grid members, such that the grid members adopt the same grid pattern as the vertical columns. That is, the vertical columns support the grid members at the points or nodes where each grid member intersects in the grid pattern. For the purposes of this disclosure, the points or junctions where the grid members intersect or connect with each other constitute nodes of the track system and correspond to the areas of the track system supported by the vertical columns. The resulting grid frame structure can be considered as a free-standing rectilinear collection of upright columns, i.e. a four-walled frame, which supports a grid formed by intersecting horizontal grid members.

[0013] The arrangement of the vertical columns provides a plurality of vertical storage columns for the storage of one or more containers in stacks. The vertical columns help guide the gripping equipment of the lifting mechanism as the gripping equipment engages the containers within the grid frame structure and lifts them toward load handling equipment operating on the grid. The size of the grid frame structure, and therefore the ability to store containers containing different items or stock keeping units (SKUs), depends largely on the number of vertical columns that span a given footprint of the grid frame structure. However, one of the biggest bottlenecks in building a fulfillment or distribution center is the erection of the grid frame structure. The time and expense of assembling the grid frame structure accounts for a large proportion of the time and expense of building a fulfillment or distribution center. The largest and most time-consuming operation involves erecting the vertical columns one by one and securing the track system to the vertical columns.

[0014] WO2019 / 157197 (Alert Innovation Inc.) attempts to address this problem by providing an automated fulfillment system that includes a plurality of storage modules, each of which includes a pair of shelf modules that include a number of defined storage locations for storage containers (also known as boxes). The shelf modules are spaced apart to allow a mobile robot to pass between the pairs of shelf modules and retrieve or deliver inventory to the storage locations. However, the automated storage system taught in WO2019 / 157197 (Alert Innovation Inc.) does not provide a dense storage system like that taught in WO2015 / 185628A (Ocado) because the shelf modules take up valuable storage space.

[0015] WO2020 / 074242 (Autostore Tech) teaches a plurality of mobile containers, each of which is equipped with an automatic storage and retrieval system comprising a grid frame structure for storing storage boxes (wherein the boxes can contain items). One of the mobile containers may be a so-called main container, which has storage columns and dedicated columns for receiving storage boxes from a transfer station and delivering the storage boxes to the transfer station. The remaining mobile containers may be so-called supply containers, which include an automatic storage and retrieval system and do not have dedicated columns for receiving storage boxes from a transfer station and delivering the storage boxes to the transfer station. Within the system, the main container can be connected to at least one supply container so that a box handling carrier can be moved from the storage grid structure of the main container to the storage grid structure of the supply container. The main container and / or the supply container can be connected to a plurality of supply containers, which in turn can be connected to a plurality of supply containers, and so on. A pivotable intermediate element is used to connect the respective rail systems of the automatic storage and retrieval systems of adjacent mobile containers.

[0016] Therefore need a kind of lattice frame structure, it allows to build lattice frame structure faster and / or more cheaply than the current lattice frame structure in the prior art.In addition, lattice frame structure should also make the available space or area for storing multiple containers maximize. Summary of the Invention

[0017] The present applicant has alleviated the above-mentioned problems by forming a grid frame structure using fewer structural components than is currently practiced as described above, while still maintaining the same structural integrity as existing grid frame structures to support the weight of one or more robotic load handling devices operating on the grid frame structure (which may weigh up to 150 kg). The present invention provides a grid frame structure assembled from a plurality of modular storage units, each of the plurality of modular storage units providing storage for a stack of a plurality of storage containers. Although WO2020 / 074242 ((Autostore Tech) provides a mobile storage system that enables multiple automated storage and retrieval systems in a mobile container to be connected side by side to increase the storage capacity of the mobile storage system. However, it does not consider taking measures to deal with the movement and / or deformation of the rail system caused by the influence of thermal expansion of the grid frame structure in one or more mobile storage units when one or more mobile storage units are assembled together. The practice of expanding the grid frame structure by assembling multiple modular storage units together to increase the storage capacity of the automated storage and retrieval system has the risk that the thermal expansion of the grid frame structure in one of the mobile storage units may generate a force sufficient to cause a chain reaction on the grid frame structure of the adjacent modular storage unit. For example, Forces generated by thermal expansion within the grid frame structure of a mobile storage unit may be transferred to adjacent mobile storage units. The cumulative effect of such forces on a number of modular storage units may cause different areas of the grid frame structure to buckle or at least deform. On a subtle level, thermal expansion of one or more rails may also cause one or more vertical members to be interconnected at their upper ends by the rails to deform. Since the vertical posts are arranged to provide storage posts in the grid frame structure, deformation in one or more vertical posts may cause gripping equipment and / or storage containers to strike the vertical posts as they are vertically guided by the vertical posts. The terms vertical member and vertical post are used interchangeably in this specification to refer to the same feature.

[0018] Although WO2020 / 074242 (Autostore Tech) attempts to provide a grid frame structure that can be easily transported and erected in remote locations, the grid frame structure in each mobile container still has the problem of needing to be assembled using the above-mentioned "component-based" method, and therefore still faces the problems of long construction time and material costs.

[0019] In contrast to a "construction-by-construction" approach (where assembly of a grid frame structure requires extensive and time-consuming adjustments to the levelness of the track or rail system to ensure reliable operation of robotic load handling equipment on the track), the grid frame structure according to the present invention is constructed from a plurality of prefabricated panels or frames, wherein each of the plurality of prefabricated panels or frames is assembled from a subset of vertical members that are reinforced together by one or more reinforcement members. For definitional purposes, in the context of constructing a grid frame structure, the term "prefabricated" is understood to encompass pre-assembled or fabricated portions of the grid frame structure prior to on-site assembly of the grid frame structure, such that the grid frame structure can be assembled at a location different from the location where the prefabricated portions of the grid frame structure are manufactured, wherein each prefabricated portion comprises a plurality of components or assemblies of the grid frame structure. The different location can be a location remote from the location where the grid frame structure is assembled, i.e., in another building, or alternatively, the assembly can be performed at the same location but in a different area of the same location, e.g., in a different area of the same building. In the context of the term "panel", a prefabricated panel is formed by reinforcing together a subset of vertical members in a single plane, for example in a single vertical plane. Preferably, the reinforcing members are horizontal reinforcing members.

[0020] Prefabricated panels or frames are assembled together in a three-dimensional grid pattern to form a plurality of modular storage units, wherein each modular storage unit is sized to store a stack of a plurality of storage containers, i.e., each modular storage unit utilizes an open storage space for the storage of a stack of a plurality of storage containers. The prefabricated modular panels are load-bearing, which means that when they are assembled together to form a supporting frame structure, they provide a load-bearing structure to support one or more load handling devices that move on a rail system mounted to the supporting frame structure. Having each prefabricated modular panel extend within a single plane also facilitates flat packing of the supporting frame structure for transport. The prefabrication of the modular panels allows the supporting frame structure to be quickly assembled on site or within a building. This has the advantage that the supporting frame structure can be constructed in an existing vacant building or warehouse.

[0021] To mitigate the effects of thermal expansion of the prefabricated frames within a single modular storage unit on adjacent modular storage units within the grid frame structure, the prefabricated frames within each modular storage unit within the grid frame structure are arranged to function as independent modular units that are sufficiently spaced apart to avoid affecting adjacent modular storage units within the assembly. This prevents forces generated by thermal expansion within a single modular storage unit from affecting the geometry of adjacent modular storage units. Because each individual modular storage unit is assembled from a plurality of prefabricated panels, the spacing between adjacent modular storage units allows the prefabricated panel components to elastically deform within the spacing without plastically deforming beyond the spacing. One of the primary consequences of thermal expansion within the grid frame structure is deformation of the tracks on which robotic load handling equipment operates. This deformation can hinder the proper movement of the robotic load handling equipment on the grid frame structure because the wheels of the load handling equipment are constrained within the rails of the track system.

[0022] In order to cope with the effects of thermal expansion of components of modular storage units, the present invention provides a lattice frame structure for supporting one or more robotic load handling devices operating on the lattice frame structure, the lattice frame structure comprising: i) a supporting frame structure comprising a plurality of prefabricated frames arranged in a three-dimensional grid pattern, the three-dimensional grid pattern comprising a plurality of modular storage units for storing stacks of a plurality of containers such that adjacent modular storage units share a common prefabricated frame, each of the plurality of prefabricated frames lying in a vertical plane and comprising a plurality of vertical members reinforced together by reinforcement members; ii) a track system for guiding movement of one or more robotic load handling devices on the grid frame structure, the track system being mounted to the supporting frame structure and comprising a plurality of tracks arranged in a grid pattern comprising a plurality of grid cells and extending across the plurality of modular storage units such that each modular storage unit in the plurality of modular storage units is configured to support a subset of two or more grid cells of the track system; The track system further comprises a track support structure comprising a plurality of track supports arranged in a grid pattern corresponding to the grid pattern of the track system, the plurality of track supports being interconnected at intersections of the plurality of track supports in the grid pattern, the track support structure being subdivided into a plurality of modular sub-frames such that each modular sub-frame of the plurality of modular sub-frames comprises a subgroup consisting of two or more grid cells of the track system, Wherein, the interconnected portions of the plurality of rail supports at the junctions between adjacent modular storage units include one or more sliding joints, so that adjacent modular sub-frames can move relative to each other along a substantially horizontal plane through the one or more sliding joints.

[0023] For the purposes of definition, the arrangement of rails and rail supports in a grid pattern comprises having a first set of parallel rails and / or rail supports extending in a first direction and a second set of parallel rails and / or rail supports extending in a second direction, the second direction being substantially perpendicular to the first direction. The interconnections at the intersections of the plurality of rail supports within a given modular sub-frame are fixedly connected together, as compared to the interconnections at the junctions of the plurality of rail supports between adjacent storage units. For the purposes of defining the present invention, the term "fixedly" is to be interpreted as meaning that there is no or little movement of more than 0.5 mm relative to each other at the intersections of the plurality of rail supports. In contrast to the component-based process for constructing a grid frame structure known in the art, the grid frame structure according to the present invention is formed by a plurality of prefabricated panels arranged in a grid pattern so that adjacent modular storage units share a common prefabricated frame. A common prefabricated framework shared between adjacent modular storage units enables a track system to extend across a plurality of modular storage units, enabling one or more robots operating on the grid frame structure to move across the plurality of modular storage units. The plurality of prefabricated frameworks arranged in a three-dimensional grid pattern define a support frame structure for supporting the track system. In addition to the need to assemble the prefabricated framework to form the support frame structure more quickly than with conventional component-based methods, there is also a need to assemble the track system more quickly. Traditionally, track systems are formed by laying individual track elements in a horizontal plane along the X and Y Cartesian directions and interconnecting the track elements with vertical members of the track system at the intersection of the track elements via cover plates (see PCT / EP2021 / 055217 in the name of Ocado Innovation Limited and WO18146304 in the name of Autostore Tech AS). Laying the individual track elements separately is not only time-consuming but also cumbersome, as the track elements need to be individually interconnected to the vertical posts.

[0024] A track system includes a track support structure comprising a plurality of track support members arranged in a grid pattern corresponding to a grid pattern of a plurality of tracks. The plurality of track support members are interconnected at intersections of the plurality of track support members in the grid pattern. To provide a track system that can be installed more quickly than conventional methods of laying individual track elements, the track support structure is subdivided into a plurality of discrete modular sub-frames. Each of the plurality of modular sub-frames includes a subset of two or more grid cells of the track system, for example, a subset of X×Y grid cells of the track system, where X and Y can be any number equal to or greater than 2. The interconnections at the intersections of the plurality of track support members within a given modular sub-frame are fixedly connected together. Thus, the track system is assembled from modular sub-frames, rather than from individual track elements. Because each modular sub-frame includes a subset of two or more grid cells of the track system, it is easier to assemble the modular sub-frames together to form the track system. Each modular sub-frame may be sized to occupy a single modular storage unit of the supporting frame structure, such that each of the plurality of modular storage units is configured to support two or more grid units of the track system. An advantage of this is that portions of the track system may be prefabricated prior to assembling the supporting frame structure. For example, subdividing the track support structure into a plurality of discrete modular sub-frames allows portions of the track system to be lifted onto the supporting frame structure. The plurality of tracks may be integrated into the track support structure, in which case both the tracks and the track supports may be simply mounted to the supporting frame structure in a single operation. Alternatively, the plurality of tracks may be mounted separately to the track support structure, which results in two operations: laying the track support structure to the supporting frame structure, and subsequently mounting the tracks to the track support structure.

[0025] Rather than fixedly connecting the interconnections of the plurality of track supports at their intersections (e.g., via bolts), the interconnections at the intersections between adjacent modular storage units can be movable via one or more sliding or movable joints. The one or more sliding or movable joints at the intersections between adjacent modular storage units allow for thermal expansion in the track system, allowing adjacent modular sub-frames to move relative to each other along a substantially horizontal plane. The one or more sliding joints at the intersections between adjacent modular storage units allow for movement in the range of 0.5 mm to 10 mm, preferably 0.5 mm to 5 mm, to accommodate thermal expansion of the track supports. In other words, the one or more sliding joints allow for greater movement between the interconnections of the track supports at the intersections between adjacent modular storage units than between the interconnections of the plurality of track supports within a given modular sub-frame. In this way, due to the movement between adjacent modular storage units via the one or more sliding joints, movement in one modular storage unit due to thermal expansion does not significantly affect the movement of adjacent modular structural units. Optionally, each of the one or more sliding joints includes a bracket (e.g., a support bracket) configured to support one or more rail supports between adjacent modular storage units so that adjacent modular sub-frames are separable. Alternatively, each of the one or more sliding joints may include a bridging member including a pin-slot arrangement in which a pin is movable within a slot.

[0026] Considering that the track support structure is subdivided into a plurality of modular sub-frames, optionally one or more sliding joints include: i) a first set of sliding joints at the junctions between adjacent modular storage units in a first direction, such that adjacent modular sub-frames are movable relative to each other along a substantially horizontal plane in the first direction; and ii) a second set of sliding joints at the junctions between adjacent modular storage units in a second direction, such that adjacent modular sub-frames are movable relative to each other along a substantially horizontal plane in the second direction, The second direction is substantially perpendicular to the first direction.

[0027] Providing first and second sets of sliding or moving joints enables adjacent modular sub-frames of the track support structure at the junction between adjacent modular storage units to move in a first direction and a second direction.

[0028] To form a grid frame structure comprising a plurality of freestanding modular storage units or modular units, one or more vertical members of adjacent prefabricated frames are connected together at the junctions between adjacent modular storage units by one or more fasteners. To enable the connected vertical members to deflect and absorb thermal expansion of the track support structure, adjacent vertical members at the junctions or junctions between adjacent modular storage units are preferably spaced apart, so that adjacent modular sub-frames are spaced apart. Because there are spaces between the vertical members at the junctions between adjacent modular storage units sharing a common prefabricated frame, the distal ends of one or more of the plurality of rails mounted to the horizontal reinforcement members of the prefabricated frame are spaced apart. This is because the surface area of the rail system extending across the plurality of modular storage units is slightly expanded due to the spaces between the vertical members. Since the vertical members are anchored to the floor, bending moments generated by thermal expansion in one or more components of the rail system are transferred to the vertical members. Since the grid frame structure is formed by a plurality of prefabricated frames, and the plurality of prefabricated frames are arranged in a manner that includes a plurality of modular storage units, The modular storage units are arranged in a grid pattern so that the vertical members of adjacent modular storage units are allowed to bend or elastically deform within the spaces between the adjacent modular storage units without affecting the vertical members of adjacent modular storage units. Bending of the vertical members at the junctions between adjacent modular storage units is absorbed by the modular sub-frames moving along their respective sliding joints. To space adjacent vertical members at the junctions between adjacent modular storage units, one or more spacers are optionally arranged between adjacent vertical members at the junctions between adjacent modular storage units that share a common prefabricated frame.

[0029] To control deflection of the vertical members in orthogonal directions (e.g., in the X-direction and in the Y-direction), each of the one or more spacers includes a first spacer member or portion and a second spacer member or portion. The first spacer member is configured to separate adjacent vertical members connected in a first direction by a first spacing, while the second spacer member is configured to separate adjacent vertical members connected in a second direction by a second spacing. At least three adjacent vertical members are connected together at the junction between adjacent modular storage units, depending on the position of the adjacent vertical members in the supporting frame structure. At the edge of the supporting frame structure, three vertical members from three separate prefabricated frames are connected in the first and second directions, i.e., two vertical members are connected to the spacer in the first direction and one vertical member is connected to the spacer in the second direction. Similarly, within the supporting frame structure, four adjacent vertical members from four separate prefabricated frames are connected to the spacer in the first and second directions. To prevent adjacent vertical members connected in the first and / or second directions from striking the storage container when the storage container is lifted through the grid unit, the first spacing and the second spacing are optionally different.

[0030] To control the deflected shape of the vertical members at the junctions between adjacent modular storage units, the one or more spacers include a plurality of spacers distributed along the longitudinal lengths of adjacent vertical members at the junctions between adjacent modular storage units sharing a common prefabricated frame. Optionally, the spacing between the vertical members between adjacent modular storage units sharing a common prefabricated frame is in the range of 5 mm to 120 mm, preferably between 10 mm and 120 mm.

[0031] To control the deflection angle of the vertical members at the junctions between adjacent modular storage units, each of the one or more sliding joints optionally includes a limiter for limiting relative movement between adjacent modular sub-frames along a substantially horizontal plane to a predetermined distance. The limiter prevents excessive movement of the modular sub-frames of the track support structure at the junctions between adjacent modular storage units, thereby preventing excessive movement or deflection of adjacent vertical members connected in the first direction and the second direction.

[0032] In order to assemble a supporting frame structure by a plurality of prefabricated frames, the plurality of prefabricated frames share a common prefabricated frame between adjacent modular storage units, the plurality of prefabricated frames are arranged to form a plurality of modular units, each of the plurality of modular units includes a connecting portion, and the connecting portion is arranged to connect with the connecting portion of the adjacent modular unit to form a plurality of modular storage units that share a common prefabricated frame between adjacent modular storage units.

[0033] Preferably, a plurality of prefabricated frames are arranged to form a first type of modular unit and a second type of modular unit, the second type of modular unit having a connecting portion configured to connect with the first type of modular unit in a first direction or a second direction to form at least a portion of a supporting frame structure, the portion comprising at least two modular storage units sharing at least one common prefabricated frame at the connecting portion of adjacent modular storage units. To form at least two modular storage units sharing a single common prefabricated frame, the first type of modular unit is optionally a closed-side modular unit and the second type of modular unit is optionally an open-side modular unit having an open side on one side of the modular unit, such that the open side of the second type of modular unit is closed by sharing a common prefabricated frame with the first type of modular unit. Alternatively, the first type of modular unit includes four prefabricated frames arranged to form a closed-side structure, and the second type of modular unit includes three prefabricated frames arranged to form a substantially U-shaped structure, the substantially U-shaped structure of the second type of modular unit being closed by sharing a common prefabricated frame with any of the closed-side structures of the first type of modular unit. Each of the plurality of modular units may be a freestanding structure capable of independent movement relative to one another, wherein movement of the track system caused by movement of one or more modular units in the first direction or the second direction is mitigated by sliding joints between adjacent modular units.

[0034] Optionally, a plurality of prefabricated frames are arranged to form a third type modular unit, wherein the third type modular unit includes at least two connecting parts, and the at least two connecting parts are configured to connect with the first type, second type and / or third type modular units in a first direction and a second direction, respectively, to form at least four modular storage units.

[0035] Optionally, the third type of modular unit is an open-sided modular unit along both sides of the modular unit, so that the open-sided modular unit along both sides of the modular unit is enclosed by sharing two common prefabricated frames with the first and / or second type of modular units between adjacent modular storage units in the first direction and the second direction.

[0036] Optionally, the third type of modular unit comprises two prefabricated frames arranged to form a substantially L-shaped structure, such that the third type of modular unit shares two common prefabricated frames between adjacent modular storage units in the first direction and the second direction.

[0037] In order to interconnect adjacent modular sub-frames of a track support structure between adjacent modular storage units via one or more sliding joints, the plurality of modular sub-frames of the track support structure include a first type of modular sub-frame and a second type of modular sub-frame, the first type of modular sub-frame being a closed-side sub-frame and the second type of modular sub-frame being an open-side sub-frame, the first type of modular sub-frame being mounted to the first type of modular unit and the second type of modular sub-frame being mounted to the second type of modular unit such that the open-side sub-frames of the second type of modular sub-frame are closed by sides of the first type of modular sub-frame at a junction between adjacent modular sub-frames comprising the one or more sliding joints in a first direction or a second direction. In this way, movement between the first type of modular sub-frame and the second type of modular sub-frame via the one or more sliding joints occurs in the first direction or the second direction. Optionally, the plurality of modular sub-frames of the track support structure further include a third type modular sub-frame, the third type modular sub-frame being an open-sided sub-frame along both sides of the sub-frame and being mounted to the third type modular unit such that the open-sided sub-frames along both sides of the sub-frame of the third type modular sub-frame are enclosed by the first type modular sub-frame and / or the second type modular sub-frame between adjacent modular storage units including one or more sliding joints in the first direction and the second direction. In this way, movement between the third type modular sub-frame and the first type modular sub-frame and / or the second type modular sub-frame occurs in the first direction and the second direction at the junction between adjacent modular storage units.

[0038] Traditionally, containers or storage boxes in a stack are guided through their respective grid cells by vertical columns at each node or intersection of a track system. These columns are typically arranged so that the track system is supported by a vertical column at each node or junction, where the tracks intersect or interconnect to form multiple storage columns for storing storage containers stacked on top of each other in a vertical stack. Therefore, when a container is lifted or hoisted toward load handling equipment operating on the track system, all four corners of the storage container engage the vertical columns to prevent the container from swaying.

[0039] Assembling prefabricated modular panels to form a three-dimensional grid frame structure creates one or more open storage spaces for accommodating stacks of multiple storage containers. The open storage space has a surface area to accommodate multiple grid cells of the track system. The removal of the vertical posts means that the containers are lifted and raised through the grid cells of the track system in free space by the loading handling equipment operating on the track system. In order to prevent the gripping equipment and any storage containers attached to the gripping equipment from swaying when being lifted through the grid cells of the track system, each of the plurality of modular storage units includes a plurality of box guides extending substantially vertically between the track system and the floor, the plurality of box guides being arranged in a pattern for accommodating stacks of storage containers between the plurality of box guides and guiding the storage containers through their respective grid cells of the track system.

[0040] Unlike the primary load-bearing columns of the prefabricated modular panels, the plurality of box guides are intended to guide handling equipment and / or storage containers through the grid cells of the track system. Preferably, each of the plurality of box guides includes two vertical box guides extending between the track system and the floor to accommodate the corners of the storage containers. The two vertical box guides are configured to accommodate the corner portions of the handling equipment and / or storage containers. Thus, four box guides would be required to accommodate the four corner portions of a standard storage container, which is generally formed of straight lines in shape.

[0041] Because each of the plurality of box guides need not be load-bearing, the box guides can be manufactured using less expensive manufacturing methods. Alternatively, the plurality of box guides are formed from a sheet metal blank folded along parallel fold lines and extending longitudinally along the sheet metal blank to form two substantially perpendicular box guides defining the two box guides. Examples of folding the sheet metal blank into the box guides include, but are not limited to, cold rolling.

[0042] While it is not necessary for the box guides to engage or accommodate all four corners of a storage container when the container is lifted toward the rail system by the lifting mechanism of the load handling equipment, in another embodiment of the present invention, the box guides are arranged to guide one or more containers in the stack only along pairs of diagonally opposite corners of the one or more containers. Because the storage containers are lifted along the diagonally opposite guides, this provides a certain level of lateral stability in the X and Y directions for the gripping device and / or the storage containers attached thereto. By guiding the gripping device and / or the storage containers attached thereto only by the diagonally opposite box guides, the number of box guides required to guide the gripping device and / or the storage containers attached thereto is reduced. In fact, the box guides can be arranged at alternating nodes in a first direction (e.g., the X direction) and a second direction (e.g., the Y direction), where the second direction is substantially perpendicular to the first direction, so that one or more containers can be stacked between two guides only at diagonally opposite corners of the storage container.

[0043] Optionally, the plurality of vertical members of each prefabricated frame are reinforced by one or more reinforcing members. The one or more reinforcing members extending between the plurality of vertical members of the prefabricated frame provide a lightweight rigid frame panel comprising a triangulated system of straight interconnected structural reinforcing elements under axial tension or compression. Preferably, the reinforcing members of each prefabricated frame in the plurality of prefabricated frames comprise one or more horizontal and / or diagonal reinforcing members. There are different arrangements of reinforcing members to provide different triangulated systems of straight interconnected structural reinforcing elements under axial tension or compression. Optionally, the one or more reinforcing members are arranged between the plurality of vertical members of the prefabricated reinforced frame in a cross reinforcement, K-shaped reinforcement, V-shaped reinforcement or eccentric reinforcement arrangement. The terms "prefabricated frame" and "prefabricated reinforced frame" are used interchangeably in the specification to represent the same features. Optionally, each prefabricated frame comprises an A-frame. At least one drag strut or collector is formed by reinforcing a plurality of vertical members by straight horizontal reinforcement members. The drag strut or collector is located where at least two vertical members are reinforced by horizontal reinforcement members at the top or bottom of two columns and is used to collect and transfer diaphragm shear forces to the columns. In order to improve the structural integrity of the supporting frame structure, each of the plurality of vertical members within a given prefabricated frame has a cross-sectional profile that is different from the cross-sectional profile of one or more horizontal and / or diagonal reinforcement members. For example, the structural integrity of the prefabricated frame can be improved by strengthening the diagonal reinforcement members (for example, by increasing the wall thickness or shape of the cross-sectional profile of the diagonal reinforcement members) compared to other structural members of the prefabricated frame. In order to further enhance the structural integrity of the prefabricated frame, each of the one or more horizontal and / or diagonal reinforcement members can be reinforced by one or more inserts.

[0044] In addition to the track support structure being modular, the plurality of tracks may also include a plurality of modular track segments, each of the plurality of modular track segments including substantially perpendicular track segment elements to provide a track surface extending in a first direction and a second direction, the second direction being substantially perpendicular to the first direction. By providing a track system in which each of the plurality of track segments is formed as a single or unitary body, the track segments provide a track surface or path extending in a transverse direction (e.g., in a cross-shaped configuration). This reduces the number of track segments required to construct the track system compared to prior art track systems, thereby simplifying the layout of the track segments on the track support structure. For example, each of the plurality of track segments may have a one-to-one relationship with a single node in the track system, meaning that only a single track segment is required at each node in the track system. A "node" in the track system is a point at which a plurality of tracks and / or track supports intersect in a grid pattern. In prior art track systems, there is a two-to-one relationship between the number of track segments and a single node in the track system, that is, there is one track segment extending in a first direction and another track segment extending in a second direction. In one embodiment that implements a one-to-one relationship between each track segment in the plurality of track segments and each node in the track system, preferably, each track segment in at least a portion of the plurality of modular track segments comprises: a) a first track section element extending in a first direction; and b) a second track segment element, the second track segment element intersecting the first track segment element and extending in the second direction, such that the track segment is configured for installation at one or more nodes of the track support structure. More preferably, each of the plurality of track segments is formed as a single body or a single-piece body. In other words, each of the plurality of track segments may be cross-shaped, having a first track segment element extending in the first direction and a second track segment element intersecting the first track segment element and extending in the second direction. The first track segment element and the second track segment element may also be referred to as lateral portions or branches of the track segment. Being formed as a single or unitary body enables the track segment to be installed at each node of the track support structure at which the track supports intersect. This eliminates the need for separate tracks or track elements extending in the first and second directions, respectively, as in prior art solutions. In addition to simplifying the laying of the plurality of tracks to the track support structure, the cross-shaped configuration of the modular track sections enables the modular track sections to span the junctions between adjacent modular storage units to provide a continuous track surface extending across adjacent modular storage units.

[0045] However, the present invention is not limited to having a one-to-one relationship between a single track segment and the number of nodes of the track system. For example, a single track segment formed as a single body can be configured to extend across multiple nodes of the track system and also provide a track surface extending in a transverse direction.

[0046] Typically in the art, to ensure that the track system is level and compensate for uneven floors, the levelness of the track system mounted to the vertical posts is adjusted by means of adjustable leveling feet disposed at the base or lower end of the vertical posts, the adjustable leveling feet including threaded shafts that can be extended or retracted relative to the base of the vertical posts. To compensate for uneven floors or ground surfaces, one or more prefabricated frames forming a supporting frame structure may be mounted to the adjustable leveling feet including threaded shafts that can be extended or retracted relative to the base of the prefabricated frames.

[0047] The present invention provides a storage and retrieval system comprising: i) a grid frame structure according to the present invention; ii) a stack of a plurality of containers, the stack of the plurality of containers being arranged in storage columns located below the rail system, wherein each storage column is located vertically below a grid cell; iii) a plurality of load handling devices for lifting and moving containers stacked in the stack, the plurality of load handling devices being remotely operated to move laterally on a track system above the storage columns to access containers passing through the grid cells, each of the plurality of load handling devices comprising: a) a wheel assembly for guiding the load handling equipment on the track system; b) a container receiving space located above the rail system; and c) A lifting device arranged to lift a single container from the stack into the container receiving space.

[0048] The present invention further provides a method for assembling a grid frame structure according to the present invention, comprising the following steps: i) assembling a plurality of prefabricated frames in a grid pattern to form a supporting frame structure comprising a plurality of modular storage units, such that adjacent modular storage units share a common prefabricated frame; ii) mounting a plurality of modular sub-frames to the supporting frame structure in a substantially vertical orientation such that adjacent modular sub-frames are interconnected at their junctions by one or more sliding joints.

[0049] The number of sliding joints at the junctions between adjacent modular storage units depends on the location of the modular sub-frames in the track support structure, which in turn depends on the number of sides on which the modular sub-frames connect to adjacent modular sub-frames in the track support structure. For example, a modular sub-frame located in the center of the track support structure connects to four adjacent modular sub-frames, with each of its four sides connecting to one of the four adjacent modular sub-frames. A modular sub-frame located at an edge of the track support structure connects to three adjacent modular sub-frames, so that three of its four sides connect to adjacent modular sub-frames, and the fourth side of the modular sub-frame forms part of the edge of the track support structure. A modular sub-frame located at a corner of the track support structure connects to two adjacent modular sub-frames, so that two of its four sides connect to adjacent modular sub-frames, and the other two sides of the modular sub-frame form part of the edge of the track support structure. Thus, within a given modular subframe, one or more sliding joints extend in orthogonal directions to accommodate movement in a first direction (x-direction) as well as a second direction. To accommodate one or more sliding joints at different sides of the modular subframe, each of the plurality of modular subframes needs to be mounted to the supporting frame structure in a substantially vertical orientation.

[0050] Optionally, the step of assembling the supporting frame structure further comprises the following steps: i) assembling four prefabricated frames to form a closed-side modular unit defining a first type of modular unit; ii) assembling a plurality of prefabricated frames into the first type modular units; The plurality of prefabricated frames include three prefabricated frames arranged in a substantially U-shaped structure to define a second type of modular unit, such that the second type of modular unit shares a common prefabricated frame with the first type of modular unit.

[0051] In the construction of a grid frame structure, a first-type modular unit can be defined as the origin of construction, with the remaining modular units constructed around this origin. The origin provides a stable structure for attaching prefabricated structures to the origin (the first-type modular unit). The remaining modular units can be assembled to the origin by separately assembling the prefabricated structures to the origin, or alternatively, the second-type modular units can be preassembled before being attached to the first-type modular units.

[0052] Optionally, the plurality of prefabricated frames further comprises two prefabricated frames arranged in a substantially L-shaped configuration to define a third type of modular unit, such that the third type of modular unit shares a common prefabricated frame with the second type of modular unit.

[0053] Optionally, the method further comprises the step of pre-assembling the third type of modular unit before assembling the third type of modular unit to the second type of modular unit. Further features of the present invention will become apparent from the detailed description with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] Further features and aspects of the present invention will become apparent from the following detailed description of illustrative embodiments with reference to the accompanying drawings, in which: FIG. 1 is a schematic diagram of a grid framework structure according to a known system.

[0055] FIG. 2 is a schematic diagram showing a top view of a stack of boxes arranged within the supporting frame structure of FIG. 1 .

[0056] 3 is a schematic diagram of a known storage system including load handling equipment operating on a grid frame structure.

[0057] FIG. 4 is a schematic perspective view of the loading handling apparatus, showing the lifting apparatus gripping the container from above.

[0058] 5( a ) and 5 ( b ) are schematic perspective cross-sectional views of the load handling apparatus of FIG. 4 , showing (a) a container accommodated in a container receiving space of the load handling apparatus, and (b) the container receiving space of the load handling apparatus.

[0059] Figure 6 is a top plan view of a portion of a known grid structure comprising four adjoining grid cells, each grid cell constituting a storage column, showing the intersections or nodes of the grid members supported by vertical columns.

[0060] Figure 7 is a perspective view showing four vertical columns making up the storage spaces or storage columns within the grid frame structure.

[0061] Figure 8 is a perspective view showing an arrangement where rails and rail supports are interconnected at their nodes or intersections by cover plates.

[0062] Figure 9 It is a three-dimensional view of the track support or grid member.

[0063] Figure 10 is a perspective view of the cover plates used to connect the vertical columns to each other and the grid members at the nodes.

[0064] Figure 11 It is a three-dimensional cross-sectional view of the vertical columns and grid components connected to each other at the nodes through cover plates.

[0065] Figure 12It is a three-dimensional image of a track or rail.

[0066] Figure 13a is a perspective view of a lattice frame structure according to an embodiment of the present invention.

[0067] Figure 13b A perspective view of the individual prefabricated frames used to assemble the supporting frame structure.

[0068] Figure 13c It is used to make Figure 13b A perspective view of the vertical columns of the prefabricated frame is shown.

[0069] Figure 13d It is used to make Figure 13c A perspective view of the diagonal reinforcement members of the prefabricated frame is shown.

[0070] Figure 13e It is used to make Figure 13d A perspective view of the horizontal reinforcement members of the prefabricated frame is shown.

[0071] Figure 14 Schematic diagram showing (a) thermal expansion of adjacent prefabricated frames in a supporting frame structure, and (b) thermal contraction of adjacent prefabricated frames in a supporting frame structure.

[0072] Figure 15a is a schematic diagram illustrating the thermal expansion of adjacent prefabricated frames spaced apart in a supporting frame structure.

[0073] Figure 15b is a schematic diagram illustrating the thermal contraction of adjacent prefabricated frames spaced apart in a supporting frame structure.

[0074] Figure 15c is a perspective view of a portion of a grid frame structure according to the present invention showing the spacing between adjacent modular storage units.

[0075] Figure 15d is a top plan perspective view of vertical columns from four separate prefabricated panels, wherein the vertical columns are connected along axis XX in a first direction and along axis YY in a second direction.

[0076] Figure 15e It is a perspective view of an embodiment of a spacer, which is used to separate adjacent vertical columns connected in a first direction and a second direction.

[0077] Figure 16 It is a three-dimensional view of the supporting frame structure of the grid frame structure shown in Figure 13.

[0078] Figure 17 It shows Figure 16Schematic diagram of a top plan view of a central support frame structure showing the arrangement of a plurality of connected modular units.

[0079] Figure 18 is a perspective view of a partially assembled modular unit of the first type of supporting frame structure, showing the assembly of the prefabricated framework.

[0080] Figure 19 It represents the assembled single modular storage unit Figure 18 A perspective view of a first type of modular unit is shown.

[0081] Figure 20 is shown to be installed to Figure 19 A perspective view of a first type of modular sub-frame of the track support structure of a first type of modular unit is shown.

[0082] Figure 21 It is a perspective view of the assembled first type modular unit and the installed first type modular sub-structure.

[0083] Figure 22 It is a perspective view of a lattice frame structure comprising two modular storage units of a support frame structure and connected modular sub-frames of a track support structure.

[0084] Figure 23 is a perspective view showing the engagement between adjacent modular sub-frames of a track system via one or more sliding or moving joints at the junction between adjacent modular storage units.

[0085] Figure 24 is a perspective view of a single sliding or moving joint for coupling adjacent modular sub-frames of a track support structure at the junction between adjacent modular storage units.

[0086] Figure 24b is a perspective view of a portion of a lattice frame structure at the junction of modular storage units showing sliding joints mounted to rail supports.

[0087] Figure 24c is a perspective view of a sliding joint member according to a second embodiment of the present invention, the sliding joint member is used in Figure 24b The junctions between adjacent modular storage units are shown to connect adjacent modular sub-frames.

[0088] Figure 24d is an underside perspective view of the intersection of the rail supports at the junction between adjacent modular storage units, showing the Figure 24c Installation of slip joint shown.

[0089] Figure 24e is Figure 24d A perspective view of the underside of the intersection of the rail supports at the junction between adjacent modular storage units is shown. Figure 24c Slip joint shown.

[0090] Figure 25 is a perspective view of a grid frame structure comprising three modular storage units of a supporting frame structure.

[0091] Figure 26 is a perspective view showing the assembly of a grid frame structure comprising four modular storage units.

[0092] Figure 27 is shown extending across Figure 26 A perspective view of the track support structure of the four modular storage units.

[0093] Figure 28 yes Figure 27 A top plan view of a grid frame structure is shown showing first, second and third types of modular sub-frames abutting at the junctions between adjacent modular storage units.

[0094] Figure 29 is a perspective view illustrating a plurality of track segments mounted to a track support structure at junctions between adjacent modular storage units.

[0095] Figure 30 is a perspective view showing the assembly of track sections to the track support structure.

[0096] Figure 31 is a perspective view showing a portion of the underlying track support structure at a node of intersecting track supports.

[0097] Figure 32 is a perspective illustration of a top plan view of a track section according to an embodiment of the present invention.

[0098] Figure 33 yes Figure 32 A perspective view of the underside of a track section is shown, showing a Figure 31 The track support structure is shown with a plurality of protrusions.

[0099] Figure 34 is a diagrammatic representation of an arrangement of track sections in a track system according to the invention.

[0100] Figure 35 is an isometric view of a grid frame structure showing a plurality of box guides arranged for guiding storage containers along diagonally opposed corners of the storage containers.

[0101] Figure 36is a perspective view illustrating a set of box guides formed from sheet metal blanks folded along parallel fold lines.

[0102] Figure 37 is a perspective view showing a portion of a prefabricated frame sandwiched between sets of box guides.

[0103] Figure 38 It shows Figure 36 A perspective view of a plurality of box guides and a cover for interfacing with a rail system is shown.

[0104] Figure 39 is a perspective view illustrating the cooperation between a cover mounted to a plurality of box guides and a rail system.

[0105] Figure 40 is a perspective view showing an arrangement of a plurality of modular crash barriers installed in Figure 27 The perimeter of the track system of the grid frame structure is shown.

[0106] Figure 41 is a perspective view illustrating the arrangement of the exterior cladding around the periphery of the supporting frame structure.

[0107] Figures 42(a) and (b) are (a) a perspective view of the AGV and lifting mechanism engaged with the prefabricated frame before the prefabricated frame is lifted, and (b) a perspective view of the orientation of the prefabricated reinforcement panels before being assembled to the supporting frame structure.

[0108] Figures 43(a) to (d) are isometric views of a grid frame structure showing: (a) a mezzanine integrated into the supporting frame structure; (b) the arrangement of modular units of the supporting frame structure around and across the mezzanine; (c) an exploded view of the interface between a first region of the grid frame structure and the mezzanine; and (d) a second region of the grid frame structure above the mezzanine and a picking station below the mezzanine.

[0109] Figure 44 is an enlarged view of a bridging element connecting to a track system between a first region of a lattice frame structure and a second region of a lattice frame structure.

[0110] Figure 45 Is a single Figure 44 A perspective view of the bridging element is shown. DETAILED DESCRIPTION

[0111] The present invention has been devised with respect to known features of storage systems, such as the grid frame structure and load handling equipment described above with reference to Figures 1 to 5 .

[0112] Figure 6shows a top view of a section or portion of a conventional track system 15 comprising four adjacent grid cells 42, Figure 7 A perspective side view of a single grid cell 42 is shown, which is supported by four vertical columns 16 to form a single storage column 44 for storing one or more containers 10 in a stack. The grid frame structure can be considered as being divided into a supporting frame structure comprising a plurality of vertical columns and a track system. The track system is supported by the supporting frame structure and comprises a plurality of grid members arranged in a grid pattern comprising a plurality of grid cells.

[0113] Each vertical column 16 is generally tubular in shape. In a horizontal cross-section of the storage column 44 shown in FIG2 , each vertical column 16 includes a hollow central portion 46 (typically having a frame-shaped cross-section). One or more box guides 48 are mounted to or formed at the corners of the hollow central portion 46, extending along the longitudinal length of the vertical column 16, to guide the movement of containers along the storage column 44. The one or more box guides 48 include two vertical container guides. The two vertical container guides are arranged to accommodate the corners of a container or stack of containers. In other words, each corner of the hollow central portion 46 defines two sides of a substantially triangular area that can accommodate the corners of a container or storage box. The corners are evenly spaced around the hollow central portion 46, so that multiple vertical columns 16 can provide multiple adjacent storage columns, wherein each vertical column 16 can be used or shared by up to four separate storage columns. Figure 7 Also shown in FIG. 1 is that each vertical post 16 is mounted on an adjustable grid leveling mechanism 19 at the bottom of the vertical post, which includes a base and a threaded shaft that can be extended or retracted to compensate for uneven floors.

[0114] A horizontal cross-section of a storage column 44 in FIG2 shows that a single storage column 44 is composed of four vertical columns 16 arranged at the corners of a container or storage box 10. A storage column 44 corresponds to a single grid cell. The cross-section of the vertical columns 16 remains constant throughout the length of the column. The perimeter of the container or storage box in the horizontal plane of FIG2 illustrates a container or storage box having four corners, and the arrangement of the four vertical columns 16 at the corners of the container or storage box within the storage column 44. The corner portions of each of the four vertical columns (one for each of the four vertical columns) ensure that the container or storage box stored in the storage column 44 is correctly positioned relative to any other containers or storage boxes stored within that column and to the stack of containers or storage boxes stored in surrounding columns. Load handling equipment (not shown) operating on the track system 15 can lift the container or storage box as it is guided along the vertical columns 16 through the grid cell 42. The vertical posts 16 serve a dual purpose: (a) structurally supporting the track system 40 , and (b) guiding the containers or storage bins 10 through their respective grid cells 42 to the correct locations.

[0115] Typically, during the assembly of a grid frame structure, a single vertical column 16 is first erected. This process of assembling a single vertical column 16 is sometimes referred to as a "component-based" method. The upper ends or tops of the vertical columns 16 are then interconnected via a plurality of grid components. Figure 6 The top plan view of the portion of the track system 15 shown in shows a series of horizontally intersecting beams or grid members 18, 20 arranged to form a plurality of rectangular frames that constitute the grid cells 42. More specifically, a first set of grid members 18 extending in a first direction X and a second set of grid members 20 extending in a second direction Y are shown, with the second set of grid members 20 extending transversely to the first set of grid members 18 in a substantially horizontal plane, i.e., the track system is represented by Cartesian coordinates in the X and Y directions. The terms "vertical upright(s)," "upright member(s)," "upright," and "upright upright(s)" are used interchangeably in the description to mean the same thing. For purposes of explaining the present invention, Figure 6 The points or junctions where the mesh components, shown as darker colored squares, intersect or cross can be defined as nodes or intersections 50. Figure 6 As can be clearly seen from the layout of at least a portion or section of a known track system 40 shown in FIG. 1 , which forms four adjacent grid cells 42 , each intersection or node 50 of the track system 40 is supported by a vertical column 16 . Figure 6 In the illustrated section, or at least portion, of the track system 40 , four adjacent grid cells are supported by nine vertical posts 16 , ie, three groups of vertical posts 16 in three rows support the track system, with each row including three nodes 50 .

[0116] Each grid member may comprise a track support 18, 20 and / or a track or rail 22a, 22b (see FIG8 ), wherein the track or rail 22a, 22b is mounted to the track support 18, 20. The load handling equipment is operable to move along the track or rail 22a, 22b of the present invention. Alternatively, the track 22a, 22b may be integrated into the track support 18, 20 as a single body, for example by extrusion. At least one grid member in the group (e.g. a single grid member) may be subdivided or divided into discrete grid elements which may be coupled or joined together to form the grid member 18, 20 extending in a first direction or in a second direction. Where the grid member comprises a track support, the track support may also be subdivided into discrete track support elements which are joined or fixedly connected together to form the track support. FIG8 shows discrete track support elements constituting a track support extending in the direction of a first axis as well as in the direction of a second axis. In Figure 9 1 and 2 show a single track support element 56 for forming track supports 18 and 20. The transverse cross-section of track supports 18 and 20 can be a solid support member with a C-shaped, U-shaped, or I-shaped cross-section, or even a double C-shaped or double U-shaped support member. In a specific embodiment of the present invention, track support element 56 is a double back-to-back C-shaped section bolted together.

[0117] At the intersection of multiple track support elements in the track system 15, a connecting plate or cover plate 58 as shown in FIG8 can be used to connect or couple or fix the individual track support elements 56 together in the first and second directions. That is, the cover plate 58 is used to connect the track support elements 56 together to the vertical columns 16. Therefore, at the intersection of multiple track support elements in the track system 15, the vertical columns 16 are connected to each other at their upper ends by the cover plate 58, that is, the cover plate is located at the node 50 of the track system 15. Figure 10 As shown, the cover plate 58 is cross-shaped with four connecting portions 60 for connection to the ends of the rail support members 56 at their intersections 50 or anywhere along the length of the rail support members 56. Figure 11 The cross-sectional profile of the node 50 is shown illustrating the interconnection of the rail support members to the vertical posts at the node via a cover plate 58. The cover plate 58 includes a socket or protrusion 62 sized to fit snugly within the hollow center portion 46 of the vertical post 16 for example. Figure 11 A plurality of vertical posts 16 are shown interconnected to the track support members. Figure 11Also shown are rail support elements 56a, 56b extending in two perpendicular directions corresponding to a first direction (x-direction) and a second direction (y-direction). Connecting portions 60 are perpendicular to one another to connect to rail support elements 56a, 56b extending in the first direction and in the second direction, respectively. Cover plate 58 is configured to be bolted to the ends of rail support elements 56a, 56b or anywhere along the length of the rail support elements to form a rigid connection with cover plate 58. Each rail support element 56a, 56b is arranged to interlock with one another at a node to form rail system 40 according to the present invention. To achieve this, the distal or opposite ends of each rail support element 56a, 56b include locking features 64 for interconnecting to corresponding locking features 66 of adjacent rail support elements. In a particular embodiment of the present invention, the opposite or distal end of one or more rail support elements includes at least one hook or tongue 64 that can be received in an opening or slot 66 between adjacent rail support elements 56 at a junction where the rail support elements intersect in the rail system 40. Figure 9 and combined Figure 11 , hooks 64 at the ends of rail support elements 56 are shown being received in openings 66 of adjacent rail support elements extending across vertical posts 16 at the junction where rail support elements 56 intersect. Here, hooks 64 are provided in openings 66 on either side of rail support element 56b. Openings 66 are located halfway along the length of rail support elements 56 so that when the rail support elements are assembled together, adjacent parallel rail support elements 56 in both the first and second directions are offset by at least one grid unit. This is demonstrated in FIG8 .

[0118] To complete the track system 40, once the track support elements are interlocked together in a grid pattern comprising track supports 18 extending in a first direction and track supports 20 extending in a second direction, the tracks 22a, 22b are mounted to the track support elements 56. The tracks 22a, 22b are assembled to the track supports 18, 20 in a snap-fit and / or slip-fit arrangement (see FIG8 ). Similar to the track supports, the tracks include a first set of tracks 22a extending in a first direction and a second set of tracks 22b extending in a second direction, the first direction being perpendicular to the second direction. The first set of tracks 22a is subdivided into a plurality of track elements 68 in the first direction so that, when assembled, adjacent parallel track elements in the first direction are offset by at least one grid unit. Similarly, the second set of tracks 22b is subdivided into a plurality of track elements 68 in the second direction so that, when assembled, adjacent track elements in the second direction are offset by at least one grid unit. This is illustrated in FIG8 . Figure 12An embodiment of a single rail element 68 is shown. As with the rail support element, multiple rail elements in the first and second directions are laid together to form rails in both directions. The rail element 68, when attached to the rail supports 18 and 20, comprises an inverted U-shaped cross-sectional profile designed to cup or cover the top of the rail supports 18 and 20. One or more lugs extending from each leg of the U-shaped profile engage the ends of the rail supports 18 and 20 in a snap-fit arrangement. Alternatively, the rails 22a and 22b may be integrated into the rail supports 18 and 20 rather than as separate components.

[0119] As can be understood from the above description, the assembly process of a grid frame structure, which involves erecting vertical columns, connecting grid members, and installing rails, is very time-consuming due to the multiple individual components required to assemble it. This process can take weeks, and in worst-case scenarios, months. With the rapid growth of e-commerce demand, particularly in the retail sector, there is a growing need for distribution centers (also known as customer fulfillment centers (CFCs)) in more locations, beyond the few serving major cities, to meet the growing demand from customers. Adding distribution centers in more locations helps shorten the last-mile logistics process of moving goods from distribution centers to their final destinations. This last-mile logistics is also a key consideration to ensure that goods, such as perishable grocery products, remain fresh at their final destination. One of the major bottlenecks in providing distribution centers in more locations is the time and cost of building the grid frame structure. When establishing a distribution center, not only is the time and cost of building the grid frame structure a concern, but the grid frame structure also needs to have the flexibility to be assembled in a number of existing locations, including existing warehouses, rather than custom-built warehouses to accommodate the grid frame structure.

[0120] The present applicants have alleviated the above-mentioned problems by forming a grid frame structure according to the present invention using fewer structural components than currently practiced as described above, while still maintaining the structural integrity of the existing grid frame structure to bear the weight of one or more robotic load handling devices operating on the grid frame structure. Compared to the above-mentioned existing grid frame structures, the grid frame structure according to the present invention is constructed from prefabricated modular components. The prefabricated modular structural components are load-bearing, which means that when the prefabricated modular structural components are assembled together to form the grid frame structure, they provide a three-dimensional load-bearing structure to support one or more load handling devices moving on a track system. The use of prefabricated modular structural components to build a grid frame structure according to the present invention enables the grid frame structure to be assembled at a much faster speed than the traditional "construction-based" method of first building individual vertical columns one by one on the floor and then installing track supports to the upper ends of the vertical columns.

[0121] Figure 13a It is a grid frame structure 80 assembled from prefabricated modular structural components according to the present invention. The grid frame structure 80 can be divided into a supporting frame structure 82 and a rail system 84 for guiding one or more robotic loading handling equipment 30 on the supporting frame structure 82. When assembling the grid frame structure 80, the supporting frame structure 82 is assembled first, and then the rail system 84 is installed to the supporting frame structure 82. The rail system 84 is raised above the ground by the supporting frame structure 82 to form an open storage space for storing stacks of multiple storage containers. The supporting frame structure 82 or the rail system 84 can be assembled from modular structural components, or both the supporting frame structure 82 and the rail system 84 can be assembled from modular structural components. In Figure 13a In the particular embodiment shown, the support frame structure 82 and the rail system 84 are assembled from prefabricated modular structural components to form the three-dimensional lattice frame structure 80 .

[0122] In a specific embodiment of the present invention, the supporting frame structure 82 is formed from a plurality of prefabricated frames or panels 86a, 86b that are arranged in a grid pattern to define a three-dimensional supporting frame structure. Prefabrication of the frames 86a, 86b involves assembling and securing the individual components of the supporting frame structure 82 together prior to erecting the supporting frame structure 82 so that the components of each prefabricated frame 86a, 86b lie in a common plane. In other words, the prefabricated frames 86a, 86b can be conceived as planar. This allows the supporting frame structure 82 to be easily assembled because the use of prefabricated frames 86a, 86b significantly reduces the time and effort required to assemble the supporting frame structure 82, as opposed to currently practiced in the art of constructing a plurality of vertical columns one by one in a "block-by-block" approach and then attaching the grid structure to the supporting frame structure.

[0123] Figure 13b The prefabricated frames 86a, 86b forming the supporting frame structure according to the illustrated embodiment of the present invention are each configured as a prefabricated reinforced frame or panel 86a, 86b including a plurality of columns or vertical members 88, which are reinforced by one or more reinforcing members 90, 92 extending between the plurality of columns 88. Figure 13bIn the particular embodiment of the present invention shown, the one or more reinforcement members 90, 92 include horizontal reinforcement members 90 and diagonal reinforcement members 92. The reinforcements allow subgroups of columns 88 to be assembled together prior to assembly in the support frame structure. To enable the prefabricated reinforcement frames 86a, 86b to be flat-packed for transport, the plurality of columns 88 of each prefabricated support frame 86a, 86b extend in a common plane and are secured together by one or more reinforcement members 90, 92. The one or more reinforcement members connecting the plurality of columns are located in the same plane as the plurality of columns, so that each prefabricated reinforcement frame is planar. Each of the plurality of columns 88 can be a solid support beam having an I-shape, H-shape, or U-shape including opposing beam flanges, or a solid support beam having a C-shape or L-shape, so that the columns can be reinforced together by one or more reinforcement members. Within a given prefabricated frame 86a, 86b, the cross-sectional profile of each of the vertical members 88, horizontal reinforcement members 90, and diagonal reinforcement members 92 can be the same or different. In a particular embodiment of the present invention, within a given prefabricated frame 86a, 86b, the cross-sectional profile of each of the vertical members 88, horizontal reinforcement members 90, and diagonal reinforcement members 92 is different. The differences in the cross-sectional profile of each of the vertical members 88, horizontal reinforcement members 90, and diagonal reinforcement members 92 within a given prefabricated frame 86a, 86b facilitate tailoring the physical properties of the support frame structure. For example, the support frame structure should have sufficient ultimate tensile strength (UTS) to prevent fracture or failure when placed in tension, while still being flexible enough to allow the support frame structure to flex or deflect when thermal expansion occurs. By prefabricating the prefabricated frames using vertical columns 88, horizontal reinforcement members 90, and diagonal reinforcement members 92 having different shaped cross-sectional profiles, the physical properties of the prefabricated frames 86a, 86b can be customized to desired physical properties.

[0124] Figures 13(c) to 13(e) illustrate vertical members, horizontal reinforcement members and diagonal reinforcement members of different cross-sectional profiles used to manufacture prefabricated frames 86a, 86b according to the present invention. Figure 13d A diagonal reinforcement member 92 is shown having a box-shaped cross-sectional profile, Figure 13e The horizontal reinforcement members are shown having a C-shaped cross-sectional profile. The cross-section of the vertical posts is shaped to provide a springback or deflection portion, and a connection portion for connection to the horizontal reinforcement members. Figure 13cAlso shown are openings 89 for connecting together the vertical members of adjacent prefabricated frames in the supporting frame structure. However, in order to reduce costs and improve the structural integrity of the prefabricated reinforcement frames without affecting the lightweight of the prefabricated supporting frames, the load-bearing members of each prefabricated reinforcement frame may have a single cross-sectional profile. For example, the load-bearing members include columns 88 and reinforcement members 90, 92, that is, the entire prefabricated reinforcement frame is formed by the same type of load-bearing members with a C-shaped cross-section. In order to reduce the cost of manufacturing the grid frame structure, each column 88 and / or reinforcement member 90, 92 may be formed from a folded metal sheet blank having one or more fold lines. Embodiments of folding the metal sheet blank to form the column 88 include, but are not limited to, cold rolling.

[0125] The plurality of columns 88 of each prefabricated reinforcement frame 88 constituting the support frame structure 82 are reinforced by horizontal reinforcement members 90 and diagonal reinforcement members 92. Figure 13b In the particular embodiment shown, a plurality of horizontal reinforcement members 90 extend between the upper and middle regions of the plurality of columns 88. The horizontal reinforcement members 90a, 90b act as load-bearing beams extending between the columns 88 (specifically, mounted at the upper ends of the columns). The horizontal reinforcement members 90 include, but are not limited to, load-bearing beams having a cross-sectional shape resembling an L (angle), a C (channel), or a tube. The horizontal reinforcement members 90 can be considered to represent chords connecting the columns 88 at their upper and / or middle regions. The reinforcement of at least two columns 88 at their upper and / or middle regions by at least one horizontal reinforcement member 90 forms at least one resistance strut or collector, as is known in the art. The resistance strut or collector is located where the horizontal beams reinforce at least two vertical columns at their upper ends and serves to collect and transfer diaphragm shear forces to the columns. In addition to the at least one horizontal reinforcement member 90 extending between the plurality of columns 88 of each prefabricated reinforcement frame 86a, 86b, at least one diagonal reinforcement member 92 may also be connected to the columns to provide additional stability to the prefabricated reinforcement frame. The reinforcement members 90, 92 extending between the plurality of columns 88 are designed to produce a similar effect to a truss under tension and compression. The reinforcement portions between the plurality of columns can be designed in different patterns, including cross reinforcement portions, K-shaped reinforcement portions, V-shaped reinforcement portions and / or eccentric reinforcement portions. Cross reinforcement portions (also known as X-bracing) are composed of two diagonal reinforcement members that cross each other. The reinforcement members in the K-bracing are arranged to form a K-shape between the plurality of columns. In Figure 13b In the specific embodiment of the present invention shown, Figure 16The pattern of reinforcement members 90, 92 connecting the plurality of columns 88 of each prefabricated reinforcement frame 86a, 86b is shown as a K-shaped reinforcement pattern that provides an A-frame. To provide the A-frame, each of the plurality of prefabricated frames 86a, 86b includes two sets of diagonal reinforcement members 92—a first set of diagonal reinforcement members 92 in the upper portion of the prefabricated frame and a second set of diagonal reinforcement members 92 in the lower portion of the prefabricated frame. The sets of diagonal reinforcement members 92 in the lower portion of the prefabricated frame extend from the horizontal reinforcement members toward the mid-region of the prefabricated frame to the lowest portion of the prefabricated frame, forming legs 94 for mounting the prefabricated frame to the floor. The reinforcement members 90, 92 are fixedly connected to the columns 88 by fasteners known in the art. These include, but are not limited to, welds, bolts, rivets, or a combination thereof. A variety of lightweight materials can be used in the prefabrication of the frames. This includes, but is not limited to, metal, plastic, or fiber reinforced composite materials. Since the grid frame structure is primarily used to store grocery items, the type of metal used in the manufacture of the box guides should be sufficiently corrosion resistant. Examples of metal include, but are not limited to, stainless steel or galvanized steel. The plurality of uprights and / or reinforcement members may be formed by folding a sheet metal blank at one or more fold lines, such as by metal stamping. To further enhance the structural integrity of the prefabricated framework, one or more inserts may be used to reinforce the vertical members 88 and / or the horizontal reinforcement members 90 and / or the diagonal reinforcement members 92. For example, where the cross-sectional profile of the horizontal reinforcement member is C-shaped, an insert (not shown) may be positioned within the C-shaped profile such that the C-shaped profile forms a cladding portion around the insert.

[0126] like Figure 16 As shown, a plurality of prefabricated frames 86a, 86b are arranged in a three-dimensional grid pattern, that is, the prefabricated frames include a first group of parallel prefabricated frames 86a and a second group of parallel prefabricated frames 86b. The first group of parallel prefabricated frames 86a extends along a first direction and the second group of parallel prefabricated frames 86b extends along a second direction, and the second direction is substantially perpendicular to the first direction, so that the plurality of prefabricated frames are arranged in a grid pattern including a plurality of modular storage units or spaces 96. The first direction and the second direction can represent the X-axis and the Y-axis of a Cartesian coordinate system. The size of each of the plurality of prefabricated frames 86a, 86b is designed so that the size of each modular storage unit 96 is capable of storing a stack of a plurality of storage containers (commonly referred to as storage boxes). As shown Figure 18As shown, connecting adjacent prefabricated frames 86a and 86b in the support frame structure 82 involves connecting one of the plurality of columns 88 of the prefabricated frame 86a extending in a first direction to one of the plurality of columns 88 of the prefabricated frame 86b extending in a second direction. Various fasteners or fixing devices known in the art can be used to connect the adjacent prefabricated frames together, including but not limited to bolts, rivets, welding, or even the use of a suitable adhesive.

[0127] In order to guide one or more robotic load handling devices on the support frame structure 82, a track system 84 is mounted to the support frame structure 82 such that the track system 84 extends across a plurality of modular storage units 96 built from a plurality of prefabricated frames 86a, 86b. The track system 84 includes a plurality of tracks arranged in a grid pattern comprising a plurality of grid cells (see Figure 27 More specifically, the first set of parallel tracks 122a extends along a first direction, and the second set of parallel tracks 122b extends along a second direction, which is substantially perpendicular to the first direction, to present a grid-like pattern (see Figure 27 and Figure 29 Because each of the plurality of modular storage units 96 of the supporting frame structure 82 is sized to accommodate a stack of a plurality of storage containers, each modular storage unit 96 of the supporting frame structure 82 is sized to accommodate a subset of two or more grid units of the rail system 84.

[0128] Figure 16 The plurality of modular storage units 96 of the illustrated support frame structure 82 form a plurality of storage spaces for storing stacks of a plurality of storage containers within each storage space of the support frame structure, i.e., an open storage space for storing stacks of a plurality of storage containers. In a specific embodiment of the present invention— Figure 26 and Figure 28In the top plan view of the grid frame structure shown, each of the plurality of modular storage units 96 of the support frame structure 82 is sized to accommodate twenty grid cells 42 of the rail system 84, i.e., a grid pattern of 5×4 grid cells. Thus, each grid cell 96 of the support frame structure 82 provides storage space for stacks of twenty storage containers. The size of each of the plurality of modular storage units is not limited to accommodating twenty grid cells of the rail system, but may also be a plurality of grid cells of the rail system, i.e., each modular storage unit 96 may accommodate a grid pattern of X×Y grid cells, where X and Y may be any number equal to or greater than 2. In other words, the ratio of the number of grid units 42 of the rail system 84 to the modular storage units 96 of the supporting frame structure 82 is X:1, where X is any integer greater than one, that is, the size of each modular storage unit in the plurality of modular storage units 96 of the supporting frame structure 82 is designed to be a subset of the grid units 42 of the supporting rail system 84, which subset includes two or more grid units 42 of the rail system 84.

[0129] When a robotic load handling device operating on the track system 84 lifts one or more storage containers from a stack of one or more storage containers stored in the modular storage units 96 of the support frame structure 82, the grid frame structure 80 further includes a plurality of box guides 98 to guide the one or more storage containers through respective grid cells 42 of the track system 84. To engage each corner of the storage container as it is guided toward a given grid cell 42, each of the plurality of box guides 98 includes two vertical box guides extending between the track system and the floor (see FIG. Figure 38 ). Two vertical box guides are configured to accommodate the corner portions of the gripping device and / or storage container. When the robotic load handling equipment running on the track lifts the storage container, the box guide extends between the node where the plurality of rails intersect in the track system and the floor in order to guide the storage container through the grid cell (see Figure 13a and Figure 39 ).

[0130] A plurality of box guides 98 extend from one or more nodes where the plurality of rails intersect in the rail system to the floor, such that storage containers are guided along the box guides and through the grid cells of the rail system. A plurality of box guides are arranged in each modular storage unit of the supporting frame structure to form a plurality of storage columns for storing stacks of a plurality of storage containers within each of the plurality of modular storage units. Typically, the plurality of box guides are arranged so that all four corners of a given storage container are guided through the grid cells, i.e., as Figure 7 As shown, each storage column includes four box guides for engaging the four corners of a given storage container in the stack. When the storage container is lifted toward the rail system by the lifting mechanism of the load handling equipment, it may not be necessary to engage or accommodate all four corners of the storage container along the box guides in order to provide lateral stability to the storage container. Figure 35 In the illustrated embodiment of the invention, a plurality of box guides 98 are arranged to engage only pairs of diagonally opposite corners of a handling device and / or container, i.e., the handling device and / or container are guided by engaging the box guides at their diagonally opposite corners. This provides a level of lateral stability in the X and Y directions to the handling device and container as the container is lifted along the diagonally opposite guides, each diagonally opposite guide accommodating a diagonally opposite corner of a storage container. Thus, compared to having box guides at all nodes of the grid structure, the box guides at Figure 35 In the illustrated embodiment of the present invention, a plurality of box guides 98 are arranged at alternating nodes in a first direction (e.g., the X direction) and a second direction (e.g., the Y direction), such that one or more containers are stacked only between and guided by two box guides. Specifically, a first set of box guides 98 are arranged at alternating nodes in the first direction (e.g., the X direction), and a second set of box guides 98 are arranged at alternating nodes in the second direction (e.g., the Y direction), such that one or more containers are stacked only between and guided by two box guides. By providing box guides at alternating nodes or intersections, only half the number of box guides is required to guide a handling device and / or storage container through a grid cell. Furthermore, when a storage container is hoisted toward a grid cell, the handling device and storage container are contained only at its two corners. Figure 35 , the spatial arrangement of box guides 98 for guiding each storage container toward the grid structure only at its diagonally opposite corners is shown in FIG. The reduced number of box guides required to guide the storage containers through the grid cells helps reduce the number of components required to build the support frame structure according to the present invention.

[0131] Compared to conventional, structurally-based approaches to grid frame construction, in which box guides are incorporated into vertical columns that are primarily load-bearing to support the track system and one or more robotic load-handling devices operating on the track system, the box guides do not need to be load-bearing. This is because the weight of the track system and the weight of the one or more robotic load-handling devices operating on the track system are supported by the prefabricated frames 86a, 86b that are arranged to form the support frame structure 82. As a result, the box guides 98 can be manufactured using lower-cost materials and / or processes. In a specific embodiment of the present invention, each of the plurality of box guides 98 is formed from a sheet metal blank 100 that includes parallel fold lines 102 extending along the longitudinal length of the sheet metal blank. The sheet metal blank is folded along the fold lines to form two substantially perpendicular box guides that define the two box guides. Figure 36 and Figure 38 , a folded sheet metal blank is shown having a central portion 104 of substantially rectangular cross-section and flanges or lips 106 projecting from the central portion 104 on either side. The flanges or lips 106 cooperate with the walls of the central portion to define two box guides. The box guide forming process can also be described as forming a substantially rectangular corrugation 104 in the sheet metal blank. One example of a forming process for manufacturing the box guides from the folded sheet metal blank is cold rolling. Given the length of the box guides, to prevent excessive deflection of the vertical box guides when guiding storage containers in the rail system as they are lifted toward the grid cells, one or more stiffeners may be incorporated into the folded sheet metal blank. The one or more stiffeners may include one or more ribs integrated into the structure of the sheet metal blank, and more specifically, into the vertical box guides. Another way of providing one or more stiffeners in a box guide is to reinforce the substantially rectangular portion of the folded sheet metal blank or the rectangular corrugated structure 104 .

[0132] Two separate folded sheet metal blanks 100 may be used to form four box guides for guiding the corners of four adjacent storage containers. Figure 36 As shown, two folded sheet metal blanks 100 are arranged opposite each other so that their respective rectangular cross-sectional center portions 104 face each other. The advantage of forming the box guides 98 individually as a set of double box guides is that they can be Figure 37 As shown, a prefabricated frame is provided to house common prefabricated structures between adjacent modular storage units. Figure 37In the figure, sets of double box guides 98 are shown on either side of the prefabricated frame 98 so that the common prefabricated frames 86a, 86b shared between adjacent modular storage units are sandwiched between the two sets of double box guides. At the perimeter of the supporting frame structure, only two guides are required at each node where the rail supports intersect.

[0133] With the above Figure 10 Different from the nodes in which the box guide 98 is fastened to the rail system using a cross-shaped cover, as shown in FIG. Figure 39 In the embodiment of the invention shown, the box guide 98 is secured to the track support 56 at a node of the track system 84 by a cover 158, as shown in FIG. Figure 39 As shown, the cover 158 is mounted to the uppermost portion of the box guide 98 and includes one or more bolts and / or pins 108. Figure 39 In the particular embodiment of the invention shown in , the cover 158 includes at least one locating pin 108 that is received in an opening 110 on the bottom side of the track support 56 where the track supports 56 intersect at the node of the track system 84. Optionally, the cover 158 is fastened to the uppermost portion of the folded sheet metal blank of the box guide by snap fastening, or optionally, welded to the uppermost portion of the folded sheet metal blank. Similar to the box guide, the cover 158 can optionally be formed from a folded sheet metal blank along a plurality of fold lines. The lowermost portion of the box guide 98 is fastened to the floor by one or more anchor bolts (not shown). The box guide is secured within the modular storage unit by tensioning the box guide between the floor and the track system. The cover can optionally include tensioning bolts 112 for tensioning the box guide between the track system and the floor. As shown Figure 39 As shown, the tensioning bolts are received in openings 112 where the rail supports intersect at the nodes of the rail system. Nuts are used to tension the box guides between the rail system and the floor. In addition, the cover 158 includes guide members 114 that cooperate with the box guides to prevent the handling equipment or storage containers from colliding with the box guides. Figure 39 The areas where the track supports intersect at the nodes of the track system are shown.Guide members 114 are configured to cooperate with the track supports 56 to provide guide surfaces for guiding box guides through the grid cells of the track system.

[0134] While arranging the prefabricated frames in a three-dimensional grid pattern to form a supporting frame structure provides structural integrity to the support rail system for one or more robotic load handling devices operating on the supporting frame structure, the direct contact of adjacent prefabricated frames in the supporting frame structure does not account for thermal expansion of the prefabricated frames. In this case, the columns or vertical members 88 of adjacent prefabricated frames in the supporting frame structure are directly connected together (e.g., by one or more fasteners) at the junction between adjacent modular storage units so that the columns or vertical members abut each other. When the prefabricated frames are securely fastened to the floor and directly connected to each other in the supporting frame structure, forces generated by thermal expansion in one or more structural members of one prefabricated frame are transferred to adjacent or neighboring prefabricated frames in the supporting frame structure. The thermal expansion in each prefabricated panel is primarily concentrated in the horizontal reinforcement members or resistance struts between the vertical columns. The expansion of the horizontal reinforcement members 90 generates forces in the horizontal direction, such as Figure 14 (a) and Figure 14 (b) shows a portion of the supporting frame structure as indicated by the arrows in the figure.

[0135] Figure 14 (a) is an example of expansion of adjacent precast frame horizontal reinforcement members 90 as shown by arrows at elevated temperatures, and Figure 14 (b) An example of the contraction effect of the horizontal reinforcement members 90 between the vertical columns 88 due to lower temperatures. If the prefabricated frames are in direct contact, the forces generated by the expansion and / or contraction of the horizontal reinforcement members 90 in one prefabricated frame will be transferred to the vertical columns 88 of the adjacent prefabricated frame. Figure 14 (a) and Figure 14 In both embodiments shown in (b), the cumulative effect of expansion and / or contraction of the horizontal reinforcement members 90 can cause deformation of the prefabricated framework, as shown by the dashed lines. Because the track system is secured to the supporting frame structure, deformation of the prefabricated framework can cause deformation of at least a portion of the track system, particularly changes in the dimensions of one or more grid cells of the track system. Because the robotic load handling devices operate on the track system, deformation of at least a portion of the track system can cause one or more of the robotic load handling devices operating on the track system to derail, or even, in the worst case, collapse onto the track system.

[0136] In order to alleviate the problem that thermal expansion in one prefabricated frame affects adjacent prefabricated frames in the supporting frame structure, thereby causing deformation of the geometric structure of the supporting frame structure, the vertical columns 88 of adjacent prefabricated frames 86a, 86b connected in the first direction and / or the second direction are spaced apart. The spacing between the connected vertical columns of adjacent prefabricated frames can purposefully cause elastic deformation of the vertical columns of the adjacent prefabricated frames when thermal expansion occurs, thereby alleviating the transmission of force to the adjacent prefabricated frames in the supporting frame structure. This can be demonstrated by the figures shown in Figures 15(a) and 15(b), wherein Figure 15(a) is an embodiment of the expansion of the horizontal reinforcement members of the adjacent prefabricated frames as shown by the arrows at an elevated temperature, while Figure 15(b) is an embodiment of the contraction effect of the horizontal reinforcement members between the vertical columns due to a lower temperature. Figure 14 Compared to (a), the spacing between adjacent prefabricated frames (particularly between adjacent vertical columns) allows the vertical columns connecting adjacent prefabricated frames to purposefully elastically deform within the available space between adjacent prefabricated frames, as shown in Figure 15(a), thereby limiting the transmission of force to adjacent prefabricated frames. This can alleviate or absorb the transmission of force between adjacent prefabricated frames. In other words, the force generated by the thermal expansion of the horizontal reinforcement members 90 between the vertical columns in one prefabricated frame is absorbed by the deformation of the vertical columns rather than being transmitted to the adjacent prefabricated frame.

[0137] The deformation pattern of the vertical columns depends on the distribution of the spacing between adjacent horizontal reinforcement members of adjacent prefabricated frames. This is because the forces generated by thermal expansion between adjacent prefabricated frames are primarily concentrated in the region where the horizontal reinforcement members of the adjacent prefabricated frames are located. Therefore, as shown in Figure 15(a), when the horizontal reinforcement members undergo thermal expansion, the spacing between adjacent horizontal reinforcement members of adjacent prefabricated frames decreases. In some cases, the distal ends of the horizontal reinforcement members of adjacent prefabricated frames abut due to thermal expansion, which is alleviated by the deformation of the vertical columns between the horizontal reinforcement members. Depending on the orientation of the prefabricated frames in the supporting frame structure, the forces generated by the thermal expansion of the horizontal reinforcement members primarily occur in the first direction (X direction) and / or the second direction (Y direction). Since the vertical columns of adjacent prefabricated frames are spatially dispersed, the deformation of the vertical columns of adjacent prefabricated frames has the effect of distributing the forces of thermal expansion among multiple prefabricated frames.

[0138] A similar effect of absorbing the thermal expansion of the horizontal reinforcement members between the vertical columns by deformation of the vertical columns also applies to the shrinkage of the horizontal reinforcement members in one or more prefabricated frames at lower temperatures (e.g., refrigeration or freezing temperatures) as shown in Figure 15(b). In this case, the shrinkage of the horizontal reinforcement members 90 pulls on their connection points with the vertical columns 88, causing the vertical columns to elastically deform as shown in Figure 15(b). Because the vertical columns of adjacent prefabricated frames connected in the first direction and / or the second direction are spaced apart, the spacing between adjacent vertical columns of adjacent prefabricated frames provides space for the deformation of the vertical columns. The spacing between adjacent vertical columns of adjacent prefabricated frames is sufficient to allow one or two adjacent vertical columns to deform elastically rather than plastically. In order to allow the vertical columns of adjacent prefabricated frames to elastically deform, the spacing between adjacent vertical columns of adjacent prefabricated frames may be in the range of 5 mm to 120 mm, preferably in the range of 10 mm to 120 mm. In all cases, the spacing between adjacent vertical columns of adjacent prefabricated frames enables thermal expansion between adjacent prefabricated frames to be significantly alleviated or absorbed rather than transferred to adjacent prefabricated frames.

[0139] Various spacers 93 may be used to space adjacent prefabricated frames in the support frame structure, including but not limited to washers of varying thickness to control the spacing of adjacent prefabricated frames. Figure 15a and Figure 15b The spacing between adjacent vertical columns of adjacent prefabricated frames can be controlled by the width of spacers 93 between adjacent vertical columns. Spacers 93 can be permanently installed between adjacent vertical columns, or alternatively, spacers 93 can be used to space adjacent vertical columns of adjacent prefabricated frames and then removed to leave gaps between adjacent vertical columns.

[0140] Figure 15c FIG. 1 shows the distribution of a plurality of spacers 93 between vertical columns 88 connected at the joints between adjacent prefabricated frames in a supporting frame structure. In a specific embodiment of the present invention, Figure 15d and Figure 15e The spacer 93 shown in FIG. 1 includes a first spacer member or portion 93b extending in a first direction along axis XX, and a second spacer member or portion 93c extending in a second direction along axis YY, with the first spacer member 93b being shown as being longer than the second spacer member 93c. Due to the different spacing lengths of a given spacer 93, the spacing of the vertical columns 88 extending in the first direction at the junction between adjacent prefabricated frames is different from the spacing of the vertical columns extending in the second direction at the junction between adjacent prefabricated frames. This can be seen from the Figure 15dThe connection of the four separate adjacent prefabricated frame vertical columns 88 in the central support frame structure is clearly seen.

[0141] Of course, the number of connected vertical columns will vary depending on their location in the supporting frame structure. For example, at the edge of the supporting frame structure, there are three connected vertical columns from three adjacent prefabricated frames, and at the corner of the supporting frame structure, there are two connected vertical columns. Figure 15d The figure shown in is a top view of the vertical columns connected inside the support frame structure with four connected vertical columns. The first spacing member 93b separates the vertical columns connected in a first direction X and the second spacing member separates the vertical columns connected in a second direction Y.

[0142] In a specific embodiment of the present invention, the first spacing members space the connected vertical columns apart by a distance of approximately 50 mm to 120 mm in the first direction, and the second spacing members space the connected vertical columns apart by a distance of approximately 10 mm to 30 mm in the second direction. Due to the arrangement of the connected vertical columns in the support frame structure, and to prevent any portion of the vertical columns from protruding into the grid cells of the track system, there is a difference in spacing length. Compared to the vertical columns connected in the first direction, the shorter spacing members (i.e., the second spacing members 93c) connect the vertical columns in the second direction more tightly together, thereby preventing any portion of the vertical columns (especially the vertical columns connected in the second direction) from protruding into the storage columns or grid cells. The difference in spacing between the vertical columns connected in the first direction and the second direction can also control the deflection of the vertical columns in the first direction and the vertical columns connected in the second direction, wherein the vertical columns connected in the first direction will experience greater deflection than the vertical columns connected in the second direction. However, the present invention is not limited to different spacings between vertical columns connected in the first direction and vertical columns connected in the second direction. The lengths in the first and second directions may be substantially the same, which mainly depends on the cross-sectional profiles of the vertical columns.

[0143] In order to install the spacer 93 between the vertical posts 88, the spacer 93 includes one or more openings 95a, 95b, 95c extending in the first direction and the second direction for receiving one or more bolts. Figure 15eIn the illustrated embodiment of the present invention, spacer 93 is formed as a single, unitary body having a first spacer member or portion 93b extending in a first direction and a second spacer member or portion 93c extending in a second direction. Spacer 93 can be formed by molding, casting, or additive manufacturing (3D printing) and can be formed from a variety of rigid materials, including but not limited to metal, plastic, or ceramic. In a specific embodiment of the present invention, spacer 93 is formed by casting, and in cases where the lattice frame structure is used to store food products, the spacer is cast from a food-grade material, such as stainless steel. Casting the spacer in stainless steel ensures that the spacer does not contaminate the stored food products. However, due to the complexity and intricacy of the spacer and the need to maintain consistent dimensional tolerances between the spacer in the first and second directions and from one connection to another on the support frame structure, the cost of casting the spacer is a concern. In a specific embodiment of the present invention, spacer 93 is cast using a lost wax process or a similar process (such as a water glass casting process). Forming the spacer as a single, unitary body improves efficiency, thereby reducing the cost of assembling the lattice frame structure according to the present invention.

[0144] Figure 15e Also shown is a flange 99 at the distal end of the first spacing member extending in the first direction. The flange 99 is shaped to abut against the outer surface of the vertical posts 88 when it is positioned between adjacent vertical posts (see FIG. Figure 15d ). The opening 95c extends through the first spacing member 93b and the flange 99. When installed between the vertical posts, the bolts are received in the openings of the spacing member and the bolts are screwed in place. Figure 15d The direction of the axis XX shown extends through the wall of the vertical column. Tightening the bolts compresses the vertical column against the flange, thereby forming a secure connection between the vertical column and the spacer. The cross-sectional profile of the vertical column connected to the spacer allows the vertical column to deflect relative to the spacer. In contrast to the first spacing member 93b, the second spacing member 93c includes two openings 95a, 95b for receiving two bolts - a first opening 95a above the first spacing member and a second opening 95b below the first spacing member. The second spacing member abuts the outer surface of the vertical column connected in the second direction and is inserted through the hole 89 in the vertical column (see Figure 13c )connect.

[0145] The position of the spacers 93 between adjacent vertical columns 88 of adjacent prefabricated frames can also control the degree of deformation of the vertical columns 88. Since expansion occurs primarily in the horizontal reinforcement members, one or more spacers are positioned between the horizontal reinforcement members to affect the deformation of the vertical columns 88. Figure 15cAs shown, a plurality of spacers 93 are distributed at regular intervals along the vertical columns in the longitudinal direction to control the deflection of the vertical columns when the prefabricated frames move due to thermal expansion. In both options, it is critical that there is space between adjacent vertical columns of adjacent prefabricated frames to allow one or more vertical columns to elastically deform without significantly distorting the overall shape of the supporting frame structure.

[0146] In order to add spacing between adjacent vertical columns of adjacent prefabricated frames of the supporting frame structure, in a specific embodiment of the present invention, the supporting frame structure is divided into a plurality of modular units or blocks, wherein each modular unit or block of the plurality of modular units or blocks can be used as a spaced-apart independent unit so that the modular units can move independently of each other in the supporting frame structure. When the modular units are assembled together, each modular unit of the plurality of modular units represents a single modular storage unit. Dividing the supporting frame structure into a plurality of modular units not only facilitates the construction of the supporting frame structure, but also allows for the flexibility of spacing one or more adjacent vertical columns of adjacent prefabricated frames to mitigate the effects of the above-mentioned thermal expansion. In order to space adjacent vertical columns in the supporting frame structure, the plurality of prefabricated frames are arranged in a grid pattern including a plurality of modular storage units so that adjacent modular storage units share a common prefabricated frame 126. This can be achieved by Figure 16 and Figure 35 An isometric view of a plurality of modular units forming four modular storage units 96 is shown, and Figure 17 The illustrated arrangement is shown as a top plan view of the prefabricated frames forming the individual modular units.

[0147] Since the geometry of each modular storage unit in the supporting frame structure is a rectilinear shape to provide a supporting frame structure in which each modular unit shares a common prefabricated frame 126 between adjacent modular storage units, three types of modular units are used that are configured to connect to each other. Figures 19 to 27, three types of modular units are shown. Each of the three types of modular units has a respective joining portion 124 that enables the modular unit to join with adjacent modular units in a first direction and / or a second direction within the supporting frame structure, thereby allowing the adjacent modular storage units to share a common prefabricated frame. To allow the three modular units to join to form a plurality of modular storage units that are enclosed and share a common prefabricated frame between the adjacent modular storage units, one of the three modular units is a closed-side modular unit, while the other two modular units are open-side modular units having an open side on at least one side of the modular unit. At least one open side of the open-side modular unit is closed by joining with a side of an adjacent modular unit within the supporting frame structure. For the purposes of defining the present invention, the three different types of modular units will be referred to as a first type of modular unit 116, a second type of modular unit 118, and a third type of modular unit 120. The second and third types of modular units 118, 120 are open-side modular units having at least one open side that is configured to join with one or more sides of adjacent modular units within the supporting frame. Since the sides of each modular unit are formed from prefabricated frames, adjacent modular units share a common prefabricated frame.

[0148] To assemble Figure 17 The support frame structure shown is a structure in which the first, second, and third types of modular units 116, 118, 120 share a common prefabricated frame 126 between adjacent modular storage units, the first type modular unit 116 includes four prefabricated frames arranged in a linear configuration to form a closed modular unit, the second type modular unit 118 includes three prefabricated frames arranged in a substantially U-shaped configuration to form an open modular unit along one side of the modular unit, and the third type modular unit 120 includes two prefabricated frames arranged in a substantially L-shaped configuration to form an open-sided modular unit along two sides of the modular unit. The components of the first, second, and third types of modular units 116, 118, 120 form a structure as shown in FIG. Figure 16 and Figure 17 At least four modular storage units are shown enclosed and share a common prefabricated frame 126 between adjacent modular storage units. Figure 17As shown in exaggerated form in FIG, adjacent modular units 116, 118, and 120 are intentionally spaced apart so that each modular unit can independently move relative to each other within the support frame structure, similar to a freestanding modular unit, to accommodate thermal expansion within the respective modular unit. The spacing between adjacent modular units provides space for elastic deformation of adjacent vertical columns 88 due to thermal expansion, which is significantly mitigated by adjacent vertical columns of adjacent prefabricated frames within the support frame structure. To provide sufficient spacing for elastic deformation of one of the adjacent vertical columns, the spacing between adjacent vertical columns in the first direction is in the range of 50 mm to 120 mm, and the spacing between adjacent vertical columns in the second direction is in the range of 10 mm to 30 mm. Figure 17 The modular units shown forming four modular storage units are composed of a single first-type modular unit 116, two second-type modular units 118, and a single third-type modular unit 120. The first-type modular unit 116 is shown connected to the two second-type modular units 118 in a first direction and a second direction, respectively. The single third-type modular unit 120 is connected to the two second-type modular units 118 in the X direction and the Y direction.

[0149] Figures 18 to 27 is a schematic diagram illustrating the assembly process of assembling a grid frame structure according to an embodiment of the present invention so that adjacent modular storage units share a common prefabricated frame. The prefabricated panels are typically presented in flat packages that are easily transported to the construction location. The location can be a warehouse or an existing building. Construction involves Figures 18 to 27 As shown, the supporting frame structure is constructed in stages using a plurality of prefabricated frames. Assembly of the supporting frame structure begins with the construction of a first modular unit 116 using four prefabricated panels 86a and 86b. For ease of description, the four prefabricated frames of the first modular unit 116 will be referred to as a first prefabricated frame 128a, a second prefabricated frame 128b, a third prefabricated frame 128c, and a fourth prefabricated frame 128d. One or more 90° angle brackets (or support brackets) may be used to ensure that the first prefabricated frame 128a lies in a substantially vertical plane before the second prefabricated frame 128b is secured to the first prefabricated frame 128a, such that the second prefabricated frame 128b lies substantially perpendicular to the first prefabricated frame (which lies in a different vertical plane), i.e., the first prefabricated frame 128a extends in the X direction, while the second prefabricated frame 128b extends in the Y direction. The 90° angle brackets act as support brackets to ensure that the first prefabricated frame 128a remains substantially vertical while the second prefabricated frame 128b is secured to the first prefabricated frame via respective adjacent vertical posts. Figure 18The illustrated 90° angle brackets 130 are in the form of right-angled frames. Two 90° angle brackets 130 are fastened to the vertical columns of the first prefabricated frame 128a. Fastening the first prefabricated frame to the second prefabricated frame involves fastening their respective vertical columns together using fasteners known in the art. Various fasteners can be used to fasten the first prefabricated frame to the second prefabricated frame, including but not limited to various bolts, screws, rivets, etc. Other fastening methods include adhesives or welding. The aforementioned spacers 93 can be used to ensure that the first prefabricated frame 128a is spaced apart from the second prefabricated frame 128b in the first and second directions to provide space for thermal expansion of their respective horizontal reinforcement members. A plurality of spacers 93 can be spatially dispersed between adjacent vertical columns of adjacent prefabricated frames to control deformation or distortion of at least one of the adjacent vertical columns during thermal expansion. In the embodiment shown in Figures 15(a) and 15(b), two spacers 93 are shown connected between vertical columns 88 to control the deformation or deflection of the vertical columns of adjacent prefabricated frames. However, the present invention is not limited to two spacers between adjacent vertical columns, and a plurality of spacers may be provided between adjacent vertical columns. Ideally, in a given prefabricated frame, the spacers are positioned between the horizontal reinforcement members connecting the vertical columns together so that deformation of the vertical columns is concentrated in the area between the horizontal reinforcement members, as shown in Figures 15(a) and 15(b).

[0150] In addition to fastening or connecting the prefabricated frames to each other, each prefabricated frame is also fastened to the floor by one or more fasteners (not shown). To facilitate fastening each of the plurality of prefabricated frames to the floor, each prefabricated frame is fastened to the floor via its respective legs 94 using one or more fasteners (e.g., anchor bolts). The third prefabricated frame 128c and the fourth prefabricated frame 128d are then fastened to the first prefabricated frame 128a and the second prefabricated frame 128b to form a straight-shaped structure or a square-shaped structure, thereby forming a structure such as Figure 19 A first modular unit 128a is shown. Figure 19 Also shown are adjacent prefabricated frame legs 94 that are joined to form a three-dimensional stable structure.

[0151] Each of the first, second, third, and fourth prefabricated frames is anchored to the floor via its respective legs 94 using one or more fasteners (e.g., anchor bolts) to form a stable, freestanding structure. Once the first modular unit 116 is secured to the floor, the second modular unit 118 and the third modular unit 120 can then be assembled around the first modular unit, as the first modular unit provides a stable structure to secure the prefabricated frames of the second and third modular units 118, 120 to the first modular unit 116. The first modular unit 116 can serve as a construction origin, and additional modular units (i.e., the second and third modular units 118, 120) are subsequently assembled around the origin to expand the number of modular storage units of the supporting frame structure in the X and Y directions. Therefore, during the construction of a grid frame structure according to an embodiment of the present invention, construction of the supporting frame structure begins with assembling the origin, and then the additional modular units are assembled onto the origin. Similar to the first type of modular units, the second type of modular units and the third type of modular units are also assembled around the origin by fixing the prefabricated frames individually to the vertical columns of the first type of modular units so as to expand the supporting frame structure in the X direction and the Y direction. Figure 22 As shown, the second type of modular unit 118 is assembled onto the first type of modular unit 116 by connecting three prefabricated frames in a substantially U-shaped configuration to one side of the first type of modular unit 116, thereby forming two modular storage units that share a common prefabricated frame 124 between adjacent modular storage units.

[0152] In order to create a supporting frame structure consisting of three modular storage units, such as Figure 25 As shown, by connecting three prefabricated frames in a generally U-shaped configuration, additional second type modular units 118 are assembled to the other side of the first type modular units to form a generally L-shaped support frame structure including three modular storage units 96. In order to form a support frame structure 82 having a straight shape and including four modular storage units 96, as shown in FIG. Figure 26As shown, the layout of the first and second modular units allows the completion of the supporting frame structure by connecting two prefabricated frames arranged in an L-shape to form a third modular unit 120. Within each structure, there are parallel sets of prefabricated frames 86a extending in a first direction (i.e., the X-direction) and parallel sets of prefabricated frames 86b extending in a second direction (i.e., the Y-direction). The first and second sets of prefabricated frames are arranged in a grid pattern encompassing a plurality of modular storage units 96. Junctions 124 at each modular unit allow adjacent modular storage units in the structure to share common prefabricated frames 126 in both the X- and Y-directions. In other words, during the construction of the supporting frame structure, a U-shaped second modular unit connects to the sides of a first modular unit, and an L-shaped third modular unit connects to both sides of an adjacent U-shaped second modular unit. This process is repeated to expand the supporting frame structure to include multiple modular storage units. By building the supporting frame structure from individual prefabricated frames starting with a first-type "origin" modular unit 116, the shape of the supporting frame structure 82, and therefore the number of modular storage units 96, can be flexibly customized and primarily depends on the number of second- and third-type modular units 118, 120 assembled onto the first-type "origin" modular unit 116. In all cases, the construction process begins by constructing the "origin" to create a stable structure for mounting the second- and third-type modular units 118, 120. Once assembled, the modular units become freestanding units that can move independently relative to each other due to the spacing between adjacent prefabricated frames. In all cases, to ensure that there is room for deflection of the vertical columns due to thermal expansion effects, assembling the second- and third-type modular units 118, 120 to the first-type modular unit 116 involves connecting the respective vertical columns of the adjacent prefabricated frames in both the first and second directions using the aforementioned spacers.

[0153] The support frame structure 82 is configured to support a rail system 84 including a plurality of rails 122a, 122b for guiding the movement of one or more robotic load handling devices on the support frame structure. In order to support the plurality of rails 122a, 122b for guiding the movement of one or more robotic load handling devices on the support frame structure, the rail system 84 according to an embodiment of the present invention further includes a rail support structure 156, which includes rail supports 156a, 156b extending in a first direction and a second direction, and the plurality of rails 122a, 122b are configured to be mounted to the rail support structure 156. Figures 29 to 34In the illustrated embodiment of the present invention, the plurality of rails 122a, 122b are divided into a plurality of rail sections 132. Each rail section 132 is formed as a single, unitary body and includes rail elements or portions 134, 136 extending in the direction of the underlying rail supports 156a, 156b to provide a rail surface extending in a first direction and a second direction. That is, each rail section 132 has a connecting portion or element 134, 136 extending in a transverse direction. For the purposes of explaining the present invention, the connecting portions or rail section elements 134, 136 may be referred to as "branches" extending in the transverse direction from the node 50. Further details of assembling the plurality of rails to the rail support structure are discussed below.

[0154] The track support structure 156 may be secured to the support frame structure 82 using a variety of fasteners known in the art. This includes, but is not limited to, various screws, nuts and bolts, rivets, and the like. The track support structure 156 is secured to the horizontal reinforcement members 90 of one or more prefabricated framing members 86a, 86b of the support frame structure. If no accommodation is provided for movement of one or more modular units of the support frame structure due to thermal expansion, one or more areas of the track support structure 156 secured to the support frame structure may deform, ultimately leading to deformation of the entire track system 84. In addition to deformation of the track system due to movement of one or more modular units of the support frame structure relative to one another, any component of the track system itself may also thermally expand or contract relative to the support frame structure. For example, as the track support structure 156 is secured to the support frame structure 82, there may be a difference in thermal expansion between the support frame structure 82 and the track system 84. In addition, the fixed interconnection of the plurality of track supports at the intersections of the track supports in the grid pattern limits the movement of the track supports relative to each other, thereby amplifying deformation of the track support structure. For the purposes of defining the present invention, "fixed" interconnection at the intersections of the plurality of track supports is intended to mean that there is no movement of more than 0.5 mm. Although, as described above, thermal expansion of the prefabricated frames of the support frame structure has been mitigated by spacing adjacent prefabricated frames relative to each other, further measures are still required to accommodate thermal expansion in one or more areas of the track system 84. In order to provide space for movement of one or more modular units 116, 118, 120 in the support frame structure 82, the track support structure 156 is further divided into a plurality of discrete modular sub-frames, each of the plurality of modular sub-frames including at least a portion of the track support structure 156, that is, each modular sub-frame is sized to accommodate a subset of two or more grid units of the track system. In order to enable the individual modular sub-frames to move relative to each other along a substantially horizontal plane in the rail system, the plurality of modular sub-frames are interconnected at the junctions 124 of adjacent modular storage units 96 by one or more sliding joints or movement joints 146 (see Figure 24). Thus, adjacent modular sub-frames are movable relative to each other in the X direction (first direction) and the Y direction (second direction) along a substantially horizontal plane via one or more sliding joints. Within a given modular sub-frame, the interconnections of a plurality of rail supports at their intersections are firmly connected together by one or more bolts, while the interconnections of the rail supports at the junctions of adjacent modular storage units include one or more movable joints to enable relative movement between adjacent modular sub-frames. Therefore, when the rail support structure moves due to thermal expansion, movement will occur at the junctions of adjacent modular sub-frames compared to the interconnections that are rigidly connected together at the intersections of the rail supports within the modular sub-frame. For the purposes of defining the present invention, movement between adjacent modular sub-frames is intended to mean movement of more than 0.5 mm, i.e., approximately 0.5 mm to 10 mm. The extent of movement of the modular sub-frames depends primarily on temperature changes in the rail system. Typically, the prefabricated frame is anchored to the floor by one or more anchor bolts so that the vertical columns at the junctions between adjacent modular storage units are spaced apart. To accommodate thermal expansion of the modular sub-frames, one or more sliding joints at the junctions of adjacent modular sub-frames may allow movement in the range of 0.5 mm to 10 mm, preferably 0.5 mm to 5 mm.

[0155] In order to enable different portions of the track support structure 156 to move independently relative to each other at the junctions of adjacent modular storage units of the support frame structure, and because the track support structure 156 is directly fastened to the support frame structure, the track support structure 156 is divided in a similar division pattern as the support frame structure 82. Similar to the modular units 116, 118, 120 of the support frame structure 82 described above, each of the plurality of modular sub-frames has a junction portion 138 that is configured to connect with adjacent modular sub-frames in the track support structure so that adjacent modular sub-frames in the track support structure share a common side therebetween. Figure 28As clearly shown in the schematic diagram of the top plan view of the mid-track support structure, the plurality of modular sub-frames include a first type modular sub-frame 140, a second type modular sub-frame 142 and a third type modular sub-frame 144, which adopt a connection mode similar to the modular units 116, 118, and 120 of the support frame structure 82, that is, each type of modular sub-frame in the first type modular sub-frame 140, the second type modular sub-frame 142 and the third type 144 modular sub-frames each have a connection portion 138 configured to be connected to each other. Each of the first, second, and third modular subframes 140, 142, 144 are mounted and / or fastened to a respective modular unit 116, 118, 120 of the supporting frame structure 82, i.e., the first modular subframe 140 is mounted to the first modular unit 116, the second modular subframe 142 is mounted to the second modular unit 118, and the third modular subframe 144 is mounted to the third modular unit 120. Because adjacent vertical columns of adjacent prefabricated frames are spaced apart, adjacent modular subframes mounted to respective modular units are also spaced apart. Adjacent modular sub-frames are separated by a distance of about 1 mm to 5 mm, preferably about 1 mm to 3 mm, and more preferably about 1.5 mm to 2 mm, compared to the spacing between the vertical posts to allow for thermal expansion and to enable the wheels of the loading and handling equipment to travel over the joints between adjacent modular sub-frames without striking the track supports.

[0156] In order to connect the first, second, and third modular sub-frames 140, 142, and 144 to form the linear track support structure 156, the first, second, and third modular sub-frames are connected in a similar manner to the modular units of the support frame structure. That is, the first modular sub-frame 140 has a closed-side outer frame structure, and the second and third modular sub-frames 142 and 144 have open-side outer frames along at least one side of the modular sub-frame. Similar to the second and third modular units 118 and 120 of the support frame structure 82 described above, the second modular sub-frame 142 is a three-sided frame that forms a substantially U-shaped outer frame structure with one open side (see FIG. 1 ). Figure 22 ), the third type of modular sub-frame 144 is a two-sided frame that forms a substantially L-shaped outer frame structure with two open sides (see Figure 26 The open sides of the second and third modular sub-frames 142 and 144 expose the ends of the rail supports.

[0157] The second modular sub-frames 142 are configured to interface with the first modular sub-frames 140, such that they share common sides. This means that the open sides of the second modular sub-frames 142 are closed by sharing sides with the first modular sub-frames 140. The third modular sub-frames 144 are configured to interface with the second modular sub-frames 142 by sharing two sides of adjacent second modular sub-frames 142 within the rail system 84. The interface between adjacent modular sub-frames corresponds to the interface between adjacent modular units in the support frame structure (i.e., between adjacent modular storage units of the support frame structure). Similar to the first modular units 116, the first modular sub-frames 140 serve as the "origin" to which the second and third modular sub-frames 142 and 144 interface.

[0158] To accommodate the movement or sliding joints 146 between adjacent modular sub-frames, one or more sliding joints are mounted or fixed to the sides that are common between adjacent modular sub-frames. Figure 20 and Figure 21 As shown, assembly of the track support structure 156 begins by attaching a first modular sub-frame 140, representing the origin of the track support structure 156, to the first modular unit 116. The first modular sub-frame 140 is then fastened to the first modular unit 116. Fastening the first modular sub-frame 140 to the first modular unit 116 involves fastening the outer frame structure of the modular sub-frame to the prefabricated horizontal reinforcement members 90 of the frame. A variety of fasteners can be used to fasten the first modular sub-frame 140 to the first modular unit 116. These include, but are not limited to, screws, nuts, and bolts. The present invention also contemplates other means of fastening the first modular sub-frame 140 to the first modular unit 116, such as adhesives, welding, and the like. Because the first modular sub-frame 140 is a closed-side modular sub-frame, one or more sliding or moving joints are mounted to one of the sides shared with the adjacent modular sub-frame.

[0159] Once the first modular sub-frame 140 is installed and secured to the first modular unit 116, as shown Figure 22As shown, the second modular sub-frame 142 is then installed and fastened to the second modular unit 142. The same type of fasteners may be used to fasten the second modular sub-frame 142 to the second modular unit 118, i.e., to the horizontal reinforcement members of the prefabricated frame. In order to enable the second modular sub-frame 142 to interface with the first modular sub-frame 140 when installed to the second modular unit 118, one or more sliding joints 146 may be accommodated between the first and second modular sub-frames 140, 142, the one or more sliding joints being configured to receive exposed ends of rail supports extending from the open sides of the second modular sub-frame 142. Figure 23 In the particular embodiment shown, the exposed ends of the track supports 156a, 156b extending from the open sides of the second type modular sub-frame 142 are shown as being received in one or more sliding joints 146 mounted to the first type modular sub-frame 140. The advantage of having one or more sliding joints support the ends of the track supports from adjacent modular sub-frames is that the track support structure can be easily assembled together while incorporating one or more sliding joints between adjacent modular sub-frames. Since the one or more sliding joints are configured to support the exposed ends of the track supports from adjacent modular sub-frames, as shown in FIG. Figure 22 As shown, the second modular sub-frame 142 can be simply lowered onto the second modular unit 118 in a substantially vertical orientation and then secured to the second modular unit 118. Not all exposed ends of the rail supports of the second modular sub-frame 142 need to be supported by the sliding joints 146. Alternatively, only some of the exposed ends of the rail supports of the second modular sub-frame need to be supported by one or more sliding joints 146. In all cases, the sliding joints or travel joints are configured to allow the modular sub-frames to be individually mounted to the supporting frame structure in a substantially vertical orientation.

[0160] exist Figure 23In the illustrated embodiment of the present invention, the exposed track supports forming the center portion of the second modular sub-frame 142 are supported by sliding joints 146. However, the track supports of the second modular sub-frames on the outside of the second modular sub-frames 142 are secured to the first modular sub-frame 140 via angle brackets 123, thereby connecting to the first modular sub-frame 140. The angle brackets 123 ensure that the outside of a given modular sub-frame is secured to the adjacent modular sub-frame in the track support structure 156, while the track supports forming the center portion of the modular sub-frame are supported on the adjacent modular sub-frame in the track support structure 156 via one or more sliding joints 146. To enable the ends of the track supports secured to the angle brackets 123 to move in a first direction (X) or a second direction (Y), depending on the orientation of the connection to the angle brackets, the angle brackets are secured to the track support ends by bolts or screws received in slots or elongated openings in the angle brackets. The slots or elongated openings allow bolts or screws that secure the ends of the rail supports to move along the slots or elongated openings.

[0161] exist Figure 24 In the illustrated embodiment of the invention, each sliding joint 146 includes a support bracket having a bottom wall 148 for supporting the end of the track support and opposing side walls 150 for preventing excessive lateral movement of the individual track supports of the second type modular sub-frames 142 when mounted to the support bracket 146. Movement of the ends of the track supports, and therefore movement between adjacent modular sub-frames, occurs as the ends of the track supports slide on the bottom walls 148 of their respective support brackets 146. The support brackets 146 are oriented so that the ends of the track supports can only move in one direction. This direction can be in a first direction (X direction) or a second direction (Y direction). In order to prevent the ends of the track supports from disengaging from the sliding joints 146, the ends of the track supports can optionally be fastened to the respective sliding joints, and more specifically to the bottom walls 148 of the sliding joints, by fasteners. Figure 24 In the illustrated embodiment of the present invention, a bottom wall 148 of a sliding joint 146 includes a slot or elongated opening 147 for receiving a bolt. The slot 147 is oriented so that the track support member engaged with the sliding joint can move in a first direction (X-direction) or a second direction (Y-direction). The elongated slot limits the movement of the modular sub-frames relative to each other in the first and / or second directions. To prevent excessive movement of the modular sub-frames in the first and second directions, movement in the first and second directions is limited to no more than 10 mm, preferably no more than 5 mm, to accommodate thermal expansion of the track system.

[0162] Rather than supporting the exposed ends of the rail supports to provide for relative movement between adjacent modular sub-frames on the supporting frame structure, in an alternative embodiment of the present invention, as Figures 24b to 24e As shown, the sliding or moving joint 146b includes an elongated member forming a bridge member 146c that spans the junction between adjacent modular sub-frames. Figure 24b The rail support is shown configured to be fixedly connected to the modular subframe at a first end 146d and a second end 146e, the second end 146e including a pin 146f that is received in a position such as a Figure 24d and Figure 24e as shown in the openings 157 in the track supports of adjacent modular sub-frames. Similar to the support brackets, relative movement between adjacent modular sub-frames occurs when the pins 146f in the openings 157 of the track supports 156a of the adjacent modular sub-frames move in the X direction or the Y direction. Similar to the first embodiment of the sliding joint including the support bracket, the movement of the pins 146f in the openings 157 is limited by the size of the opening in the track support 156a. The openings 157 are slightly enlarged or elongated compared to the pins 146f to limit the movement of the pins in the openings to no more than 5 mm, preferably to no more than 3 mm, and more preferably to 1 mm to 2 mm to accommodate thermal expansion of the track system. The first end 146d of the bridging member is fixed to the track support so that the pins 146f at the second end 146e are facing upward. When the pins as Figure 24d and Figure 24e This enables an adjacent modular sub-frame to be mounted to the supporting frame structure in a substantially vertical orientation when shown received in the openings of the rail supports of an adjacent modular sub-frame.

[0163] As an alternative or in addition to having the pins of the bridging members facing upwards, as Figure 24b As shown, the bridging member 146c can also be connected across the adjacent modular sub-frames after the modular sub-frames are installed to their respective modular units of the support frame structure. In this case, the pin at the second end of the bridging member faces downward to be received in the opening of the track support of the adjacent modular sub-frame in a substantially vertical orientation. In both cases, the installation of the sliding joint or movement joint with the modular sub-frame is in a substantially vertical orientation. Similar to the support bracket, the bridging member can be formed from metal (such as stainless steel). However, the present invention is not limited to the above-mentioned movement or sliding joint, and can also be any type of movement or sliding joint that allows movement in the range of 0.5 mm to 10 mm between adjacent modular sub-frames.

[0164] The spacing between adjacent sliding joints 146 corresponds to the spacing between adjacent parallel track supports 156a, 156b. Movement between adjacent modular units (in this case, the first and second modular units 116, 118) due to thermal expansion is absorbed by the movement of the exposed ends of the track supports along their respective sliding joints 146. Depending on the size of the support frame structure and the number of modular storage units that the support frame structure occupies, as shown in FIG. Figure 25 and 26 As shown, the above-described process of mounting the modular sub-frames of the track support structure 156 to the first and second types of modular units 116 , 118 may be repeated for the other modular sub-frames.

[0165] Figure 26 The embodiment shows that the third modular sub-frame 144 is mounted to the third modular unit 120 by connecting the two open sides of its L-shaped open frame structure to complete the linear structure of the track support structure 156 including four modular storage units. Similar to the second modular sub-frame 142, the third modular sub-frame 144 is lowered onto the third modular unit 120 so that the exposed ends of the track supports at their respective open sides connect with the second modular sub-frame 142 by being received in the support brackets 146 (support brackets 146 are mounted to the sides of the second modular sub-frame 142) (as shown in FIG. Figure 26 ), or by connecting to a bridging member according to a second embodiment of a sliding joint and connecting to a second type of modular sub-frame 142 (as shown in FIG. Figure 24 (b to e)).

[0166] Movement between adjacent modular sub-frames depends on the number of joints between the adjacent modular sub-frames. For the second type of modular sub-frame 142, the joints are configured to allow movement in only one direction (e.g., X or Y) depending on the orientation of the support bracket or bridge member forming the sliding joint 146 with the first type of modular sub-frame 140 at the joint. In the case of the third type of modular sub-frame 144, which has two joints, movement in two directions (e.g., X and Y) is allowed because it is connected to adjacent modular sub-frames on both sides. Therefore, the track support structure includes a first set of sliding or moving joints to enable movement between adjacent modular sub-frames 140, 142, 144 in the X direction, and a second set of sliding or moving joints to enable movement between adjacent modular sub-frames 140, 142, 144 in the Y direction. Figure 28The arrows in the figure indicate the directions of movement between adjacent modular sub-frames in the X and Y directions. By connecting adjacent modular sub-frames along the X and Y directions, movement between adjacent modular sub-frames in both the X and Y directions is permitted within a substantially horizontal plane. The modularity of the support frame structure and the track support structure (which have similar connecting portions) enables the assembly of grid frame structures of varying shapes and sizes.

[0167] No track system is complete without a plurality of tracks for guiding one or more robotic load handling devices on the track system. Each track in the plurality of tracks is contoured to provide a single track surface to enable a single robotic load handling device to travel on the track, or to provide a double track to enable two load handling devices to pass each other on the same track. Where the plurality of tracks are contoured to provide a single track, the track includes opposing lips (one lip on one side of the track and the other lip on the other side of the track) along the length of the track to guide or constrain lateral movement of each wheel on the track. Where the plurality of tracks are contoured to provide a double track (e.g., Figure 32 ), the track includes two pairs of lips 152 along the length of the track to allow the wheels of adjacent robotic load handling devices to pass each other in both directions on the same track. To provide the two pairs of lips, the track typically includes a central ridge or lip 154 and lips 152 on either side of the central ridge 154.

[0168] Similar to the track support structure 156 described above, the plurality of tracks 106 includes a first set of parallel tracks 122a extending in a first direction and a second set of parallel tracks 122b extending in a second direction, the second direction being substantially perpendicular to the first direction, to form a grid-like pattern similar to that of a track system. Because the plurality of tracks are mounted to the track support structure 156, the grid pattern of the plurality of tracks corresponds to the grid pattern of the track support structure. While the specific embodiment describes the plurality of tracks being mounted to the track support structure, the plurality of tracks may alternatively be integrated into the track support structure, in which case the plurality of tracks are divided similarly to the modular subframes of the track support structure 156 described above. In other words, each of the first, second, and third modular subframes 140, 142, 144 of the track support structure 156 includes a portion of the track integrated into the respective modular subframe.

[0169] Similar to the support frame structure and the track support structure, the plurality of tracks can be modularized into a plurality of track segments 132 to facilitate assembly of the plurality of tracks on the track support structure. Each of the plurality of track segments is cross-shaped, and this property results in a one-to-one relationship between each track segment 132 and each node 50 of the track system, that is, only a single track segment 132 occupies a single node of the track system, rather than at least two track segments in the prior art track system as described above and shown in Figure 8. In other words, the intersection of the track segment elements 134, 136 of a given track segment 132 corresponds to a node of the track system. Adjacent track segments in the track system are arranged so that their respective track segment elements 134, 136 extend in the area between the nodes 50 of the track system, that is, they meet at a point 160 between the intersections of the tracks. More specifically, the distal ends 162 of the track segment elements (branches) 134, 136 of adjacent track segments 132 meet in an area substantially centered or midway between adjacent nodes 50 of the track system. This also speeds up the assembly of each track segment onto the track support structure 156 because, when assembling a plurality of tracks onto the track support structure 156, a single track segment can be installed at each node 50 of the track support structure 156. For example, because the track segments are not constrained to a specific orientation on the track support structure, each adjacent track segment can be installed onto the underlying track support in a different orientation. In other words, due to the symmetry (e.g., rotational symmetry) of the track segments of the present invention, the track segments can be installed onto the track support structure in a variety of different orientations without affecting their ability to connect to adjacent track segments on the track support structure. In the context of the present invention, rotational symmetry refers to the ability to angularly rotate a track segment so that the rotated track segment overlaps with the non-rotated track segment. In the case where the grid cells are square (the tracks are of equal length in the X and Y directions), the rotational symmetry of the track segments is such that the angle of rotational symmetry is 90°, which means that the track segments can be rotated four times and still coincide with themselves, i.e. the order of symmetry is four. In the case where the grid cells are rectangular, the order of rotational symmetry of the track segments is two. The advantage of this is that the number of track segments of different shapes required to assemble the tracks for the main part of the grid structure is reduced, i.e. the "jigsaw" effect where the track segments have specific positions in the track system is eliminated, and thereby the time to assemble the track on the track support structure is reduced. In addition, compared to the tracks of the prior art, the number of tooling designs required to mold the track segments of the present invention is smaller, so the tooling costs for manufacturing the track segments will be significantly reduced.

[0170] A plurality of track segments 132 are mounted to the underlying track support structure to provide a continuous track surface between adjacent track segments for movement of one or more robotic load handling devices on the grid frame structure 104. Modularizing the plurality of tracks into a plurality of cross-shaped track segments also allows for coverage of areas of the track support structure that are prone to irregularities. Areas of the track system that are prone to irregularities are at the track system nodes (where the plurality of track supports intersect within the track support structure) and / or between adjacent modular sub-frames. The areas of the track support structure between the nodes 50 are less susceptible to any differences in height variations of the connected track supports 156a, 156b than at the nodes described above. By extending the track segment elements of adjacent track segments in the areas between the track system nodes, they are largely unaffected by any irregularities in the underlying track support structure between the nodes 50. Consequently, the track support structure is largely flat and uninterrupted in the areas between the nodes.

[0171] Because the joints between adjacent modular subframes in the track support structure are configured with one or more sliding joints to accommodate movement between modular units in the support frame structure due to thermal expansion, the joints between adjacent modular subframes are also prone to unevenness. For example, individually attaching rails to each modular subframe of the track support structure causes adjacent rails in the track system to abut at the joints between adjacent modular subframes of the track support structure, which can create slight steps in the track system between adjacent modular subframes. When a robotic load handling device approaches a junction or joint between adjacent modular subframes, the wheels of the robotic load handling device may bump or hit the edge of the rails as the wheels cross the junction. Although the vertical displacement of the wheels when the robotic load handling device travels across the junction is small, this up-and-down impact on the wheels is one of the main causes of noise and vibration generated by the traveling robotic load handling device. In the worst case, the jolting of the wheels on the track or rails can cause wear not only to the wheels or tires of the robotic load handling device, but also to the rails, to the point of damaging one or both of the wheels and the rails. To reduce the presence of steps in the track system, particularly at the junctions between adjacent modular sub-frames of the track support structure, one or more track segments are mounted to the track support structure at the junctions between adjacent modular sub-frames such that one or more portions of a given track segment extend across the junction (see Figure 29Because the exposed ends of the track supports are arranged to be received in the support brackets of the sliding joints (which are mounted to the adjacent modular sub-frames at the junction), the cross-shaped shape of each track section allows the track section to be mounted to the track support structure at the junction of adjacent modular sub-frames, so that the respective track section elements of the track section can extend across the junction. This has the effect of masking any imperfections or edges in the underlying track support structure and shifting any junctions between adjacent track sections to areas of the track system that are less prone to such height changes, namely between the nodes of the track system.

[0172] Although the track sections with a cross shape help alleviate the unevenness of the underlying track support structure, the distal ends of the track section elements 134, 136 of adjacent track sections 132 are still prone to unevenness, especially when they intersect at nodes. The distal ends of the track section elements 134, 136 may form steps at the junctions between adjacent track sections 132. If left untreated, this may cause vertical displacement of the wheels of the load handling equipment traveling on the junctions between the connected adjacent track sections 132. In order to alleviate this step problem, as Figure 32 and Figure 33 As shown, the distal ends 162 of the track elements are beveled or tapered. The distal ends 162 of the track segment elements include at least one tapered edge that changes the conventional 90° angle cut to a substantially 45° angled edge. This allows the wheels of the load handling equipment to partially contact the beveled end of the second track segment element before they have completely passed the edge of the first track segment element. This provides a gradual transition between adjacent track segments and prevents the wheels from becoming trapped in any gaps between the distal ends of adjacent track segments.

[0173] refer to Figure 13a , the grid frame structure 80 can be viewed as a self-supporting rectilinear collection of prefabricated reinforcement frames (which supports the track system formed by intersecting horizontal track supports and tracks), i.e., a four-walled frame. Therefore, track segments of different shapes are required to cover different areas of the track support structure 156. For ease of description, the different areas of the grid structure may be referred to as corner portions 164, peripheral portions 166, and center portions 168. The corner portions 164 of the track segments provide a two-way junction in the track system, the peripheral portions 166 of the track segments provide a three-way junction in the track system, and the center portions 168 of the track segments provide a four-way junction in the track system. Figure 34 The simplified diagram of the graphic of the track sections in shows different areas of the track system 84 , where the track system has a straight shape. Figure 34The simplified diagram of the track segments shown in FIG is not drawn to scale and is for illustration purposes only. The track segments 132 at the corner portions 164 of the track system 84 are shown with different shaded areas, and each track segment 164 at the corner has two track segment elements 134, 136, i.e., two branches, extending in the X-direction and the Y-direction of the track system 84, respectively. The track segments 132 at the peripheral portion 166 of the track system 84 are shown with different shaded areas. Figure 34 In the particular embodiment of the invention shown, each track section 166 at the periphery of the track comprises three track section elements 134, 136, i.e. three branches. Figure 32 In the illustrated embodiment, the track segment 166 at the periphery may have two track segment elements 134, 136 extending in opposite directions in a first direction and a third track segment element 134, 136 extending in a second direction, or may have two track segment elements 134, 136 extending in opposite directions in the second direction and a third track segment element 134, 136 extending in the first direction. The track segment 166 at the periphery is not limited to having three track elements or branches 134, 136 and may include more than three track segment elements, depending on whether the periphery extends across more than one node 50 in the track system 84. A node 50 represents the area where elements or branches 134, 136 of a single track segment in the track system 84 intersect. For example, the periphery may include two track segment element branches extending in opposite directions in a first direction and multiple track elements (i.e., more than three branches) extending in a second direction, for connecting or intersecting with an adjacent track segment 84 in the central portion of the grid structure.

[0174] like Figure 34 As is clear from the schematic diagram shown, the main parts of the track system all belong to the central part of the track system, wherein each track segment 132 is in the shape of a cross, having track segment elements 134, 136 separated or extending in transverse directions, i.e., a first direction (X) and a second direction (Y). Figure 34 In all of the different shapes of track segments 164, 166, 168 in the particular embodiment shown, there is a one-to-one relationship between each track segment in the plurality of track segments and each node 50 of the track system 84. For example, at the corners of the track system, there is a one-to-one relationship between a track segment 164 and a node 50. Similarly, at the perimeter of the track system, there is a one-to-one relationship between each track segment 166 and each node 50.

[0175] However, because a single track segment can extend across more than one node in a track system, the present invention is not limited to a one-to-one relationship between each track segment and each node in the plurality of track segments. For example, the branches or track elements 134, 136 of one or more track segments 132 can be sized to extend across one or more nodes of the track system. Larger track segments 132 mean fewer track segments 132 are required to form the track system 84 (i.e., to assemble the track system together). The distal ends 162 of one or more track segment elements 134, 136 of adjacent track segments extend and meet in the area between the nodes of the track system 84, as this is an area of the track system where the underlying track support structure 156 is less susceptible to any vertical displacement. In all cases, each track segment 164, 166, 168 is a single, unitary body having a transversely extending portion or element 134, 136 to provide a track surface or path for load handling equipment to move along the transversely extending track system. A single-piece track section with a track surface or path extending in a transverse direction significantly reduces the complexity and number of parts required to assemble the lattice frame structure according to the present invention. A variety of materials can be used to manufacture the track section, including various metals (e.g., aluminum), plastics (e.g., nylon), and / or composite materials.

[0176] While plastic materials offer the advantage of being able to achieve tight dimensional tolerances due to their malleability, one disadvantage of using plastic materials is the inability to conduct static electricity, which accumulates on the track surface due to contact with the wheels (primarily formed of non-conductive materials) of the load handling equipment, particularly the tires, to the ground. To overcome this disadvantage, in a specific embodiment of the present invention, the plastic material is rendered conductive by incorporating or mixing a conductive material, thereby allowing the track section to be made from a composite material. For example, conductive fillers can be mixed with the plastic material before molding to render the plastic material conductive. Known examples of conductive fillers include, but are not limited to, carbon (e.g., graphite) and metallic fillers (e.g., copper, silver, iron, etc.). The conductive filler can be in the form of particles or fibers. For example, conductive fillers ranging from 20% to 50% by weight can be added to the plastic material to render it conductive. Alternatively, conductors can be insert-molded into the plastic material to provide a continuous conductive path within the track.

[0177] In order to secure the plurality of rails to the rail support structure, each rail segment 132 may be snap-fitted onto the rail support structure. Figure 33 The underside of the track segment 132 shown in FIG. 1 includes one or more lugs or protrusions 170 configured to snap fit to the track supports 156a, 156b. Figure 30 and Figure 31As shown, one or more lugs 170 may include a bead or protruding edge 172 arranged to deflect and be received in a snap-fit arrangement in one or more openings 174 of opposing sidewalls (or vertical elements) of the track supports 156a, 156b. Figure 30 and Figure 31 The specific snap-fit feature shown in the drawings is a cantilevered snap-fit. However, other forms of snap-fit connections known in the art for securing track sections to track supports are also suitable for use with the present invention. Likewise, other forms of securing track sections to track supports besides snap-fit joints are also suitable for use with the present invention, such as using fasteners or adhesives.

[0178] In addition to the thermal expansion of the various components of the support frame structure 82 and the track support structure 156 described above, one or more of the plurality of tracks 122a, 122b may also experience thermal expansion in different temperature environments. This is particularly true when the plurality of tracks are individually mounted to the track support structure. Where the tracks are constructed of a plastic material and the track support structure is primarily constructed of metal, there may be differences in the coefficients of thermal expansion between the plurality of tracks and the underlying track support structure 156, leading to differences in movement between the two components due to thermal expansion. When each of the plurality of track segments 132 includes track segment elements 134, 136 extending in a substantially transverse direction, relative movement between one or more of the plurality of track segment elements and the underlying track support structure is primarily concentrated in the region surrounding the track segment elements 134, 136 extending from the nodes of the track segment 132. A node in a track segment refers to the region where the track segment elements intersect within a given track segment. When the plurality of tracks are securely fastened to the underlying track support structure, differential movement between one or more of the plurality of tracks and the underlying track supports 156a, 156b due to differential thermal expansion between the tracks and the track supports may cause deformation of the one or more tracks. For example, when the underlying track supports thermally expand more than the tracks, the forces generated by the thermal expansion of the track supports may tend to affect the connection between the tracks and the track supports. In a worst-case scenario, the differential thermal expansion between the tracks and the track supports may cause the connection between the tracks to fail, and in a worst-case scenario, cause one or more tracks to peel or detach from the track support. Because the plurality of track segments 132 are snap-fit to the track support structure 156, failure of the connection between one or more of the plurality of tracks and one or more of the underlying track supports primarily occurs at the snap-fit joints between the plurality of tracks and the track support structure.

[0179] In order to alleviate the problem of relative movement between the plurality of tracks and the underlying track support structure due to thermal expansion, the connection between each track segment and the underlying track support includes a thermal expansion joint, which includes a sliding or moving joint. When the connection between each of the plurality of track segments and the underlying track support structure includes a snap-fit joint, the snap-fit joint between the track segment and the track support is configured such that the connection allows one or more track segment elements to expand or contract relative to the underlying track support in a substantially horizontal direction, i.e., along the plane of the track system, but cannot move in a substantially vertical direction to prevent the track segment from detaching from the underlying track support. In order to accommodate the thermal expansion joint within the snap-fit joint, one or more openings 174 in the opposing side walls of the track support are enlarged in one or more directions to allow the lug or protrusion 170 to move within the one or more openings 174 of the track support. Figure 31 In the illustrated embodiment of the present invention, each of the one or more openings 174 comprises a slot in an opposing sidewall of the track support. The slot is oriented such that its longest edge (the slot length) extends in the longitudinal direction of the underlying track support, while its shortest edge (i.e., the slot width) extends substantially perpendicular to the longitudinal length of the underlying track support. The slot orientation enables the lug or protrusion 170 engaging the slot 174 to move longitudinally along the slot, thereby allowing the track segment elements 134, 136 attached to the slot to expand or contract relative to the underlying track support. It is also reasonable that thermal expansion or contraction of the underlying track support may cause the slot to move relative to the lug or protrusion 170 engaged therein. The present invention also contemplates various other ways of incorporating sliding or moving joints into the connection between one or more of the plurality of rails and the underlying track support structure. For example, the connection between each of the plurality of rails and the underlying track support structure may include one or more slides, such as telescoping drawer slides. Another way to provide one or more sliding joints between each of a plurality of track sections (particularly track section elements of a track section) includes replacing one or more slots in opposing sidewalls of a track support with recesses extending along the longitudinal length of the track support and configured to mate with lugs or protrusions of the track in a sliding arrangement. Similar to the one or more slots, the one or more lugs or protrusions of the track section are configured to snap fit with the recesses.

[0180] To allow for thermal expansion of one or more of the plurality of track segments in the track system, the distal ends 162 of the track segment elements of adjacent track segments are spaced apart. This spacing is sufficient to allow the track elements of the adjacent track segments to expand on the underlying track supports so that their respective distal ends 162 can connect or abut without bending. This spacing is also dependent on the diameter of the wheels of the robotic load handling equipment operating on the track system. If the spacing between the distal ends of adjacent track elements is too large compared to the wheel diameter, it can create a step between adjacent track segment elements, causing the wheels of the robotic load handling equipment to bump or hit the ends of the track segment elements and, in the worst case, to become trapped or fall into the gap created by the spacing between adjacent track segment elements. The spacing should be sufficient to allow the wheels of the robotic load handling equipment to bridge the gap created by the spacing between the distal ends 162 of adjacent track segments 132 without excessive wheel bumping, but not so large that the wheels become trapped or fall into the gap. In a particular embodiment of the present invention, the spacing between distal ends 162 of adjacent track elements of adjacent track segments in the track system provides a gap 176 that is in the range of 0.5 mm to 5 mm, preferably 1 mm to 3 mm, and more preferably 1.5 mm to 3 mm, compared to the spacing between adjacent vertical posts of adjacent prefabricated frames in the support frame structure. The spacing between distal ends of the track elements is primarily affected by thermal expansion of the one or more prefabricated frames of the support frame structure. Typically, for a wheel having a diameter of approximately 120 mm, a spacing of 6 mm can be achieved without the wheel being excessively bumped or sunk into the gap.

[0181] The track section elements of the track section are configured as follows Figure 32 The dual track shown includes two ridges or recesses 155 and a central ridge 154. The two ridges or recesses 155 run side by side along the longitudinal length of each track segment element 134, 136 for receiving and guiding the wheels of a robotic load handling device. The central ridge 154 runs parallel to the two ridges or recesses 155. The recesses 155 on either side of the central ridge 154 provide a path for engagement of the wheels of the robotic load handling device. Each track segment element 134, 136 for guiding the wheels of the robotic load handling device includes two lips 152, one on each side of the wheel. For the dual track, there are two pairs of lips 152 running side by side along the longitudinal length of the track for guiding the two pairs of wheels. This ensures that two load handling devices can pass each other in both the X and Y directions when operating on the dual track in different orientations on the same track segment. In order to allow one or more load handling equipment to pass through the intersection or junction of the track section (corresponding to the node of the track system), that is, through the intersection, the intersection or junction of the track includes Figure 32 Small islands 178 are shown to guide the wheels in a lateral direction. This is particularly noticeable in areas where the tracks intersect or converge, primarily around the center portion of the track system. The track system of the present invention is not limited to dual tracks; the track elements can be configured as a single track including a single ridge or depression formed by a pair of lips on either side of the track for guiding a single wheel along the track.

[0182] One or more crash barriers 180 may optionally surround at least a portion of the perimeter of the track system 84 to prevent one or more robotic load handling equipment operating on the track system from crossing outside the track system. In order to maintain the modular nature of the grid frame structure and maintain the ability to flat pack the grid frame structure, the crash barriers 180 may also be modular. The crash barrier 180 is formed as a prefabricated frame or panel including a lower portion 182 and an upper portion 184, the lower portion 182 being used to be mounted to the supporting frame structure 82, and the upper portion 184 extending above the track system to form a barrier when mounted to the supporting frame structure. The prefabricated frame is different from the prefabricated frame used to build the supporting frame structure described above. In order to distinguish it from the prefabricated frame of the supporting frame structure, the prefabricated frame forming the crash barrier is referred to as a crash panel. Since the weight of the robotic load handling equipment can exceed 100 kg and the supporting frame structure is load-bearing, the crash panel is mounted to and supported by the supporting frame structure. As Figure 40 As shown, the lower portion 182 includes vertical members that extend downwardly to connect to the vertical posts of the support frame structure, and the upper portion 184 includes one or more horizontal members for reinforcing the vertical members. The impact panels can be fastened to the vertical posts, and thus to the support frame structure, using various fasteners known in the art. These include, but are not limited to, bolts, screws, and the like. Alternatively, brackets or clamps can be used to fasten the impact panels to the support frame structure. A plurality of impact panels are fastened around the outer peripheral edge of the track system, such that each impact panel extends above the track system to form a protective fence or barrier surrounding the perimeter of the track system.

[0183] like Figure 41As shown, one or more outer walls of the supporting frame structure 82 may be clad with one or more solid wall panels 186 to enclose the interior space of the supporting frame structure. The one or more solid walls 186 may be insulated to provide a thermal barrier to prevent heat from escaping the interior space of the supporting frame structure 82. In situations where the contents of the storage container are temperature-sensitive (e.g., grocery items), the insulating cladding 186 surrounding the outer walls of the supporting frame structure 82 is advantageous in preventing heat from transferring between the interior and exterior of the supporting frame structure 82. For example, the interior space of the supporting frame structure 82 may be a refrigerated compartment operating within a temperature range of substantially 0°C to substantially 5°C, or a freezer compartment operating within a temperature range of substantially -25°C to substantially 0°C (preferably, between substantially -21°C to substantially -18°C). The outer walls of the supporting frame structure may also be clad to enhance the aesthetics of the supporting frame structure.

[0184] Since one or more load handling devices operate on the track system, it is important that the track system is located in a substantially horizontal plane as this will affect the direction in which the storage containers or storage boxes are lifted into the correct position through the grid cells. If the level of the track system deviates from the horizontal plane, this will not only put pressure on the one or more robotic load handling devices traveling on the track system, but will also cause the lifting tethers to swing to the side depending on the direction of the deviation and, in the worst case, will prevent the gripping device from engaging the container or storage box below. The problem will be even more serious if the floor used to install the grid frame structure is uneven. One or more columns and / or guides of the prefabricated reinforcement frame can be mounted on an adjustable grid leveling mechanism (not shown) for adjusting the level of the track system. The level of the track system mounted on the columns can be adjusted by providing adjustable leveling feet at the base or lower end of the vertical columns and / or box guides to compensate for uneven floors. The level of the track system can be adjusted by adjusting the adjustable leveling feet at the base of one or more vertical posts and / or box guides in the grid frame structure and checking the level of the track system at the top of the grid frame structure at each adjustment (for example by using a suitable level measuring instrument, such as a laser level as is known in the art).

[0185] Assembling a grid frame structure according to the present invention involves assembling a plurality of prefabricated modular panels into a grid pattern comprising a plurality of modular grid units, each of which provides storage space for stacks of multiple storage containers. The prefabricated frames can be prefabricated on-site or at a remote location and then transported to the location where the supporting frame structure is assembled. For example, prefabrication can involve reinforcing a plurality of vertical columns on-site with one or more reinforcement members. Prefabrication of the frames can be performed manually or automatically. Lifting equipment can be used to orient and position the prefabricated frames together. The lifting equipment can be operated manually or automatically. Figures 42(a) and 42(b) illustrate an embodiment of an automated guided vehicle (AGV) 188 including a tool or gimbal 190 that is specifically adapted to engage with the prefabricated frames 86a, 86b and is oriented for assembly into the supporting frame structure 82 according to the present invention. The gimbal 190 is defined as a pivoting support that allows an object to rotate about an axis. Figure 42a As shown, the gimbal 190 is connected to the lifting mechanism via lifting arms 192 to enable the prefabricated frames 86a, 86b to be lifted into position where they can be fastened to the existing prefabricated frames in the supporting frame structure. Figure 42a The support surface 194 shown mounted on the legs presents the prefabricated frame to the gimbal of the lifting device. The support surface 194 may include a specially designed fixture (not shown) to facilitate prefabrication of the frame. For example, in the case of a prefabricated reinforced frame, a specially designed fixture may be used to properly align the plurality of columns prior to reinforcement by one or more reinforcement members.

[0186] Once the prefabricated frames are engaged with the gimbal, a lifting mechanism is able to lift the prefabricated frames off the support surface 194, allowing the AGV to be driven to the desired location on site. The gimbal allows the prefabricated frame panels to be oriented for assembly to adjacent prefabricated panels. Multiple AGVs can be controlled by a control system to coordinate the assembly of a plurality of prefabricated frames that are assembled into a supporting frame structure. The connection of adjacent prefabricated frames involves the use of several fasteners, typically including but not limited to one or more bolts, welds, rivets or adhesives. When the prefabricated frames are presented to one of the other prefabricated frames in the supporting frame structure, the prefabricated frames can be fastened together manually or automatically.

[0187] In addition to assembling prefabricated frames together, one or more AGVs can also be used to assemble prefabricated modular sub-frames together to form a track support structure. Individual prefabricated modular sub-frames can be fastened to the modular units using one or more fasteners, such as bolts, rivets, welds, or adhesives. Once the track support structure 156 has been assembled, multiple track segments can then be assembled onto the track support structure to complete the track system of the lattice frame structure. When the individual track segments include snap-fit features as described above, the individual track segments can snap-fit into place at the nodes of the track support structure to form the track system. The transverse portions of the individual track segments help conceal any underlying imperfections in the track support structure, particularly at the nodes where the track support members intersect within the track support structure. Prefabricating the components of the lattice frame structure prior to assembly significantly reduces the time required to construct the lattice frame structure, compared to known lattice frame structure assembly methods, which first construct individual columns and interconnect their top ends with vertical columns extending in orthogonal directions. Other advantages include: Because sections of the track support structure are prefabricated prior to assembly, virtually no adjustments to the track supports are required on site, ensuring that the grid unit size remains consistent throughout the track system. Modular sub-frames can be prefabricated using specially designed jigs to ensure that individual grid units are "square" and / or properly aligned before being installed into the supporting frame structure.

[0188] To access the contents of storage containers, most grid columns are storage columns, i.e., grid columns that store storage containers in stacks. However, a grid frame structure typically includes at least one grid column that is not used to store storage containers, but rather includes a location or grid cell 42 where load handling equipment can lower and / or pick up storage containers, allowing them to be transported to a second location (not shown in the prior art figures) where they can be accessed from outside the grid or transported into or out of the grid. In the art, such locations or grid cells are often referred to as "ports," and the grid columns where they are located can be referred to as "delivery columns" 196 (see FIG. 46 ). The storage grid includes two delivery columns. The first delivery column can, for example, include a dedicated drop port 198, at which a container handling vehicle can lower a storage container to be transported via the delivery column and further lower it to an access station or transfer station. The second delivery column can include a dedicated pickup port 200, at which a container handling vehicle can pick up a storage container that has been transported from the access station or transfer station via the second delivery column. The storage container is delivered to the access station and exits the access station via the first and second delivery columns, respectively (see Figure 43a ).

[0189] Once a customer order is received, a loading handling device, which is movable on rails, is instructed to pick up a storage container containing the order items from a stack of the grid frame structure and transport the storage box via a delivery column to a picking station 202 where the items can be removed from the storage box. Typically, the loading handling device transports the storage box or container to a box lifting device integrated into the grid frame structure. The mechanism of the box lifting device lowers the storage box or container to the picking station 202. At the picking station, the items are removed from the storage box. Picking can be done manually or by a robot as taught in GB2524383 (Ocado Innovation Limited). After the items are removed from the storage box, the storage box is transported to a second box lifting device and then lifted to a pick-up port at the grid level to be retrieved by the loading handling device and transported back to its position within the grid frame structure.

[0190] In order to enable the load handling equipment to lower storage containers to the picking station 202 or pick up storage containers from the picking station 202, a separate area is set up near the storage column to accommodate the access station. Typically, the separate area is set up by adding a mezzanine 204 supported by vertical beams to the adjacent grid frame structure. The mezzanine provides a separate area to accommodate one or more service stations, such as one or more picking stations. Typically, the separate area is an aisle with grid frame structures on both sides. A rail system from the adjacent grid frame structure extends across the top of the mezzanine to connect to the rail system on either side of the mezzanine 204 so that the rail system is located in a substantially horizontal plane. One or more delivery ports and / or picking ports are assigned to one or more grid cells of the rail system extending across the mezzanine so that load handling equipment running on the rail system can lower or pick up storage containers from the picking station below. Because the track system extends across the mezzanine, the grid frame structure 212 on top of the mezzanine will be shallower than the grid frame structures 210 on either side of the mezzanine, that is, it can only accommodate one or two layers of containers in the stack. Typically, the mezzanine is a continuous structure supported by vertical beams and runs the length of the track system 84. The vertical beams supporting the mezzanine abut the grid frame structures on either side of the mezzanine. In addition to one or more picking stations 202, the separate area formed by the mezzanine can also accommodate various other stations, including but not limited to: charging stations for charging rechargeable batteries (which power the load handling equipment on the grid) and service stations for performing routine maintenance on the load handling equipment. However, the problem with continuous structures is that they lack flexibility and cannot expand the mezzanine and the surrounding grid frame structure without replacing the mezzanine. Typically, the mezzanine is built first as a continuous structure, and then the grid frame structure is assembled around the mezzanine. The shape and footprint of the grid frame structure are largely affected by the shape and footprint of the mezzanine. Since the shape or footprint of the mezzanine is fixed, the process of assembling the grid frame structure around the mezzanine is not suitable for flexible expansion of the storage capacity of the grid frame structure because this would require redesigning the mezzanine to accommodate additional storage columns.

[0191] Compared with a continuous structure, the sandwich 204 according to the present invention can be constructed in a modular manner as shown in Figures 43(a) to 43(d). The modularity of the sandwich 204 allows the sandwich to be constructed in a modular manner. Figure 43c The segments 205 shown are assembled to meet the increasing service demands of the grid frame structure 80. Thus, as the footprint of the grid frame structure increases to provide greater storage capacity, the mezzanine 204 can also be constructed in separate segments 205 along with the grid frame structure. Figure 43cIn the illustrated embodiment of the present invention, the mezzanine is constructed from individual discrete segments 205, eliminating the need to calibrate the size of the mezzanine before assembling the grid frame structure. Because the grid frame structure of the present invention is modular, the mezzanine can be easily connected to the grid frame structure and constructed simultaneously with the grid frame structure. The modularity of the mezzanine means that grid frame structures of varying sizes and shapes can be assembled and connected to the mezzanine.

[0192] Assembly of the supporting frame structure involves assembling a plurality of discrete modular blocks or units (i.e., first, second, and third modular units 116, 118, 120) to interface with a plurality of modular units extending across the mezzanine (see Figure 43b ).like Figure 43b As shown, the support frame structure includes a first region 210 and a second region 212. The first region 210 of the support frame structure surrounds the interlayer 204, and the second region 212 of the support frame structure extends across the interlayer 204. Figure 43b As shown, the first region of the supporting frame structure is at a different height than the second region 212 of the supporting frame structure extending across the mezzanine 204, such that the track system extending across the first and second regions of the supporting frame structure lies in a substantially horizontal plane. In this manner, the modular units comprising the first region 210 of the supporting frame structure have a different height than the modular units comprising the second region 212 of the supporting frame structure to accommodate the height of the mezzanine. Figure 43d is an isometric view of a second area of a supporting frame structure supported by a sandwich according to the invention. Figure 43d Also shown is a delivery column 196 extending from the rail system above the mezzanine to one or more picking stations 202 below the mezzanine. Each storage column above the mezzanine has a capacity of storing up to two storage containers. To understand this more intuitively, a typical storage container has a height ranging from 350 mm to 400 mm.

[0193] exist Figure 43a and Figure 43d In the illustrated embodiment, the first region 210 of the support frame structure 210 has storage capacity for storing a plurality of stacks of storage containers, wherein each stack of storage containers can accommodate up to twenty-one storage containers. Similarly, the second region 212 of the support frame structure has storage capacity for storing a plurality of stacks of storage containers, wherein each stack of storage containers can accommodate up to two storage containers. The modular nature of the interlayer 204 allows it to be adapted to support frame structures of different sizes and shapes. For example, Figure 43a and Figure 43bAs shown, the storage capacity of the lattice frame structure can be increased simply by connecting further modular units to the existing lattice frame structure. The modular nature of the mezzanine means that it can be assembled together with further modular units of the supporting frame structure.

[0194] In addition to the first and second regions of the supporting frame structure, the track system extending across the supporting frame structure also includes a first region 206 and a second region 208. The first region 206 of the track system extends across the first region 210 of the supporting frame structure, and the second region 208 of the track system extends across the second region 212 of the supporting frame structure. The first region 210 of the track system can be connected to the second region 212 of the track system via one or more sliding or moving joints as described above. The one or more sliding joints connecting the first and second regions of the track system enable the first region 210 of the supporting frame structure to move independently of the second region 212 of the supporting frame structure. For example, during an earthquake, ground movement can cause the supporting frame structure to vibrate. Because the first region 210 of the supporting frame structure is higher than the second region 212, the first region of the supporting frame structure may vibrate more significantly than the second region of the supporting frame structure when the ground moves. If the first and second regions of the supporting frame structure are unable to move independently, there is a risk that the first region of the supporting frame structure will exert excessive force on the second region of the supporting frame structure. In a worst-case scenario, the force may be so great that it may cause structural damage to the supporting frame structure. One or more sliding joints disposed between the first region 206 and the second region 208 of the track system enable the first region of the supporting frame structure to move independently of the second region of the supporting frame structure.

[0195] In order to incorporate one or more sliding joints between the first and second regions of the track system, the interconnection of the plurality of track supports at the junction between the first and second regions of the track system includes one or more sliding joints. In a specific embodiment of the present invention, the junction region 214 comprising the plurality of joined track supports bridges the first and second regions of the track system (see Figure 43c ). The joined track supports connect the first and second regions of the track system via one or more sliding or moving joints. The one or more sliding or moving joints may be the same sliding or moving joints as described above at the junctions of the modular storage units. The joined track supports bridging the first and second regions of the track system are shown in FIG. Figure 44In the embodiment of the present invention, a plurality of bridge elements 220 are provided, which extend across the junction area 214 in the first direction or the second direction. Each bridge element of the plurality of bridge elements is configured to receive a single rail element extending across the bridge element to enable the load handling equipment to move between the first area and the second area of the rail system. Figure 30 Similar to the rail elements described, individual rail elements may be mounted to the bridge elements via snap-fit joints.

[0196] As an alternative or in addition to connecting the first and second regions of the track system with one or more sliding joints, the junction between the first and second regions of the track system can include one or more mechanical safety devices configured to disconnect or break when an applied load equals or exceeds a predetermined load that is lower than the load that breaks the interconnection at the intersection of the plurality of track supports. This allows the first region of the track system to separate from the second region of the track system when the applied load exceeds the predetermined load. One or more mechanical safety devices 222 connect the bridging element 220 to the first and second regions 206, 208 of the track system. Due to the separation between the first and second regions of the support frame structure, disconnection of the track system at the junction separates the grid frame structure surrounding the mezzanine from the grid frame structure extending across the mezzanine. For purposes of defining the present invention, the grid frame structure comprising the first region 206 of the track system and the first region 210 of the support frame structure is referred to as the first region 216 of the grid frame structure. Similarly, the lattice frame structure including the second region 208 of the track system and the second region 212 of the support frame structure is referred to as the second region 218 of the lattice frame structure. When the load applied to the mechanical safety device is too great (e.g., during an earthquake), the first region 216 of the lattice frame structure is configured to separate from the second region 218 of the lattice frame structure so that they can move independently.

[0197] To enable the first region 210 of the grid frame structure to move independently of the second region 212 of the grid frame structure, a spacing L is also present between the first and second regions of the support frame structure, which are bridged by a junction 214. The spacing L can be one or more grid cells of the track system. Vertical members 88 adjacent to the mezzanine 204 are spaced apart from the mezzanine so that movement of the vertical members 88 in the first region of the support frame structure does not affect movement of the mezzanine 204. The only connection between the first and second regions of the support frame structure is through the junction or junction region 214 of the track system, and more specifically, through the connection of the plurality of track supports in the junction region 214.

[0198] One or more mechanical safety devices may be incorporated into one or more sliding joints bridging the first and second regions of the rail system. Figure 24c The sliding joint shown, the pin 146f which may be received in the opening 157 of the track support may be arranged to disconnect or break when a load applied in the lateral direction exceeds a predetermined load. Alternatively, each of the plurality of bridging elements is connected to a respective track support in the first region and the second region of the track system by one or more bolts, the one or more bolts having a breaking zone configured to break when the predetermined load is applied. Typically, during an earthquake, the predetermined load has a load path in a horizontal plane. The ground movement caused by the earthquake may cause the grid frame structure to oscillate in the X and Y directions in the horizontal plane. In order to accommodate movement of the grid frame structure in the X and Y directions, the mechanical safety device 222 may include sliding surfaces that are opposed to each other, such as Figure 45 As shown. The opposing sliding surfaces are configured to slide relative to each other when an applied load exceeds a predetermined load, thereby causing the first region of the lattice frame structure to separate from the second region of the lattice frame structure. The coefficient of friction of the opposing sliding surfaces enables the sliding surfaces to slide relative to each other when the applied load exceeds the predetermined load. In extreme cases, when the applied force exceeds the predetermined force, the sliding surfaces will separate or "pop open." To enable the mechanical safety device 222 to separate when the applied load exceeds the predetermined load, in the above two embodiments, the bridging element 222 includes a first portion 224a and a second portion 224b connected together by one or more sliding joint-type mechanical safety devices.

[0199] In the manufacture of the prefabricated frames, prefabricated modular subframes and / or components used in the track sections, various materials may be used, including metals (e.g. stainless steel, galvanized steel, aluminum), plastics or fiber composite materials.

Claims

1. A lattice frame structure for supporting one or more robotic load handling devices operating on the lattice frame structure, the lattice frame structure comprising: i) a supporting frame structure comprising a plurality of prefabricated frames arranged in a three-dimensional grid pattern, the three-dimensional grid pattern comprising a plurality of modular storage units for storing stacks of a plurality of containers such that adjacent modular storage units share a common prefabricated frame, each of the plurality of prefabricated frames lying in a vertical plane and comprising a plurality of vertical members reinforced by reinforcement members; ii) a track system for guiding movement of the one or more robotic load handling devices on the grid frame structure, the track system being mounted to the support frame structure and comprising a plurality of tracks arranged in a grid pattern comprising a plurality of grid cells and extending across the plurality of modular storage units such that each of the plurality of modular storage units supports a subset of two or more grid cells of the track system; wherein the track system further comprises a track support structure, the track support structure comprising a plurality of track supports arranged in a grid pattern corresponding to the grid pattern of the track system, the plurality of track supports being interconnected at intersections of the plurality of track supports in the grid pattern, the track support structure being subdivided into a plurality of modular sub-frames, such that each of the plurality of modular sub-frames comprises a subgroup consisting of the two or more grid units of the track system, Wherein, the interconnected portions of the plurality of rail supports at the junctions between adjacent modular storage units include one or more sliding joints, so that adjacent modular sub-frames can move relative to each other along a substantially horizontal plane through the one or more sliding joints.

2. The grid frame structure according to claim 1, wherein: The one or more sliding joints include: i) a first set of sliding joints at the junctions between adjacent modular storage units in a first direction such that the adjacent modular sub-frames are movable relative to each other along the substantially horizontal plane in the first direction; and ii) a second set of sliding joints at said junctions between said adjacent modular storage units in a second direction such that said adjacent modular sub-frames are movable relative to each other along said substantially horizontal plane in said second direction, The second direction is substantially perpendicular to the first direction.

3. The grid frame structure according to claim 1 or 2, wherein: The supporting frame structure is arranged such that one or more vertical members of adjacent prefabricated frames are connected together at the junction between adjacent modular storage units by one or more fasteners.

4. The grid frame structure according to claim 3, wherein: One or more spacers are arranged between adjacent vertical members at the junction between adjacent modular storage units.

5. The grid frame structure according to claim 3, wherein: Each of the one or more spacers includes a first spacer member and a second spacer member, wherein the first spacer member is configured to separate adjacent vertical members connected in the first direction into a first interval, and the second spacer member is configured to separate adjacent vertical members connected in the second direction into a second interval.

6. The grid frame structure according to claim 5, wherein: The first interval is different from the second interval.

7. A lattice frame structure according to any one of claims 4 to 6, wherein: The one or more spacers include a plurality of spacers distributed along the longitudinal lengths of the adjacent vertical members at the junction between the adjacent modular storage units.

8. A lattice frame structure as claimed in any preceding claim, wherein: The plurality of prefabricated frames are arranged to form a first type of modular unit and a second type of modular unit, wherein the second type of modular unit has a connecting portion configured to connect with the first type of modular unit to form at least a portion of the supporting frame structure including at least two modular storage units, and the at least two modular storage units share at least one common prefabricated frame at the connecting portion of adjacent modular storage units.

9. The grid frame structure according to claim 8, wherein: The first type of modular unit is a closed-side modular unit, and the second type of modular unit is an open-side modular unit having an open side on one side of the modular unit, so that the open side of the second type of modular unit is configured to be closed by sharing the common prefabricated frame with the first type of modular unit.

10. The grid frame structure according to claim 9, wherein: The first type of modular unit comprises four prefabricated frames arranged to form a closed side structure, and the second type of modular unit comprises three prefabricated frames arranged to form a substantially U-shaped structure, and the substantially U-shaped structure of the second type of modular unit is closed by sharing the common prefabricated frame with any one of the closed side structures of the first type of modular unit.

11. A lattice frame structure according to any one of claims 8 to 10, wherein: The plurality of modular sub-frames of the track support structure include a first type of modular sub-frame and a second type of modular sub-frame, the first type of modular sub-frame being a closed-side sub-frame and the second type of modular sub-frame being an open-side sub-frame, the first type of modular sub-frame being configured to be mounted to the first type of modular unit and the second type of modular sub-frame being configured to be mounted to the second type of modular unit such that the open-side sub-frame of the second type of modular sub-frame is closed by a side of the first type of modular sub-frame at a junction between adjacent modular sub-frames comprising the one or more sliding joints.

12. A lattice frame structure according to any one of claims 8 to 11, wherein: The plurality of prefabricated frames are arranged to form a third type of modular unit, the third type of modular unit comprising at least two connecting parts, the at least two connecting parts being configured to connect with the first type of modular unit, the second type of modular unit and / or the third type of modular unit to form at least four modular storage units.

13. The lattice frame structure according to claim 12, wherein: The third type of modular unit is an open-sided modular unit along both sides of the modular unit, so that the open-sided modular unit along the two sides of the modular unit is enclosed by sharing two common prefabricated frames with the first type of modular unit and / or the second type of modular unit between adjacent modular storage units.

14. The lattice frame structure according to claim 12 or 13, wherein: The third type of modular unit comprises two prefabricated frames arranged to form a substantially L-shaped structure.

15. A lattice frame structure according to any one of claims 12 to 14, wherein: The plurality of modular sub-frames of the track support structure further include a third type of modular sub-frame, which is an open-sided sub-frame along both sides of the sub-frame and is configured to be mounted to the third type of modular unit so that the open-sided sub-frames along both sides of the sub-frame of the third type of modular sub-frame are configured to be enclosed by respective sides of the first type of modular sub-frame and / or the second type of modular sub-frame between adjacent modular storage units including the one or more sliding joints.

16. A lattice frame structure as claimed in any one of claims 12 to 15, wherein: The first type of modular unit and / or the second type of modular unit and / or the third type of modular unit is a freestanding substructure.

17. A lattice frame structure as claimed in any preceding claim, wherein: Each of the plurality of modular storage units includes a plurality of box guides extending substantially vertically between the rail system and the floor, the plurality of box guides being arranged in a pattern for accommodating stacks of storage containers between the plurality of box guides and being arranged to guide storage containers through respective grid cells of the rail system.

18. The lattice frame structure according to claim 18, wherein: Each box guide of the plurality of box guides includes two vertical box guides extending longitudinally along the length of the box guide.

19. A lattice frame structure as claimed in any preceding claim, wherein: Each of the prefabricated frames comprises an A-frame.

20. The lattice frame structure according to claim 19, wherein: The plurality of vertical members of each of the prefabricated frames are reinforced by one or more horizontal reinforcement members and / or diagonal reinforcement members.

21. The lattice frame structure according to claim 20, wherein: The cross-sectional profile of each of the plurality of vertical members within a given prefabricated frame is different from the cross-sectional profile of the one or more horizontal reinforcement members and / or diagonal reinforcement members.

22. The lattice frame structure according to claim 20 or 21, wherein: Each of the one or more horizontal reinforcement members and / or diagonal reinforcement members is reinforced by one or more inserts.

23. A lattice frame structure as claimed in any preceding claim, wherein: The plurality of rails are configured to be mounted or integrated into the rail support structure.

24. The lattice frame structure of claim 23, wherein: The plurality of tracks comprises a plurality of modular track sections, each of the plurality of modular track sections comprising substantially vertical track section elements so as to provide a track surface extending in a vertical direction.

25. The lattice frame structure of claim 24, wherein: Each modular track section of the plurality of modular track sections is formed as a single unitary body.

26. A lattice frame structure as claimed in any preceding claim, wherein: Each of the one or more sliding joints includes a limiter for limiting relative movement between adjacent modular sub-frames along the substantially horizontal plane to a predetermined distance.

27. A storage and retrieval system, comprising: i) a lattice frame structure as defined in any of claims 1 to 26; ii) a stack of a plurality of containers, the stack of the plurality of containers being arranged in storage columns located below the rail system (106), wherein each storage column is located vertically below a grid cell; iii) a plurality of load handling devices for lifting and moving containers stacked in the stack, the plurality of load handling devices being remotely operated to move laterally on the track system (106) above the storage columns to access the containers passing through the grid cells, each of the plurality of load handling devices comprising: a) a wheel assembly for guiding the load handling equipment on the track system; b) a container receiving space located above the rail system; and c) A lifting device arranged to lift a single container from a stack into the container receiving space.

28. A method of assembling a lattice frame structure as defined in any of claims 1 to 26, the method comprising the steps of: i) assembling the plurality of prefabricated frames in a grid pattern to form a supporting frame structure comprising a plurality of modular storage units such that adjacent modular storage units share a common prefabricated frame; ii) mounting the plurality of modular sub-frames to the supporting frame structure in a substantially vertical orientation such that adjacent modular sub-frames are interconnected at their junctions via the one or more sliding joints.

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