Storage and retrieval system

Abstract

A storage and retrieval system comprising: a first region (100) comprising a storage structure (1) comprising: a plurality of horizontal members arranged to form a grid pattern defining a plurality of grid cells; a plurality of upright members (3) configured to support the horizontal members (5, 7) from below to define a storage area below the grid cell for storing a stack of storage containers (9); a second region (200) separated from the first region (100) by a partition (150), where the partition comprises an opening (152) such that the first region (100) is in fluid communication with the second region (200); a channel (160) extending from an associated grid cell (14a) of the storage structure into the second region (200) via an opening (152) in the partition (150) such that the storage container can be moved between the first region (100) and the second region (200) via the channel (160); and a dehumidifier system (300) configured to draw in and dehumidify air from the second area (200), and to discharge the dehumidified air into the first area (100).

Description

Technical Field

[0001] The present invention relates to a storage and retrieval system including a robotic load handling device operating on a storage structure for handling storage containers stacked in the storage structure. Background Art

[0002] Some commercial and industrial activities require systems that can store and retrieve large quantities of different products. WO2015019055A1 describes a storage and retrieval system in which items are stored in storage containers, and the storage containers are arranged in stacks within a storage structure. The system further includes a remotely operated load handling device configured to move on tracks located on top of the storage structure. In order to pick or place down storage containers stored in the storage structure, each load handling device is equipped with a gripper device for releasably holding the storage container and a lifting assembly for raising and lowering the gripper device. To fulfill a customer order, a storage container containing the ordered product is picked from the storage structure and placed down at a picking station, where the ordered product is removed from the storage container and placed into a delivery container. The storage container is then picked from the picking station and returned for storage in the storage structure. The picking station is typically located below or immediately adjacent to a portion of the storage structure so that the storage container can be efficiently moved between the storage structure and the picking station.

[0003] In the context of grocery sales operations, there is a need to automate the storage and retrieval of various food products. While the storage and retrieval systems described above are typically deployed for the storage and retrieval of ambient and refrigerated foods, there are challenges associated with the automated storage and retrieval of frozen foods, which require lower temperatures (typically -18°C or lower) than ambient and refrigerated goods for safe storage. For example, while the environment in an isolated freezer may be relatively easy to control, the freezer section in a more extensive storage and retrieval system may be open to other sections of the system operating in different environments, and therefore the freezer section may be more difficult to control. There may also be issues related to the comfort, health and safety of human workers when working in freezing temperatures. Summary of the Invention

[0004] The present invention provides a storage and retrieval system comprising: The first area includes a storage structure, and the storage structure includes: a plurality of horizontal members arranged to form a grid pattern defining a plurality of grid cells; a plurality of upright members configured to support the horizontal members from below to define a storage area below the grid cells for storing stacks of storage containers; a second region separated from the first region by a partition, wherein the partition includes an opening to place the first region in fluid communication with the second region; a channel extending from an associated grid cell of the storage structure through the opening in the divider into the second region so that storage containers can be moved between the first region and the second region via the channel; and A dehumidifier system is configured to draw in air from the second zone, dehumidify the air, and discharge the dehumidified air into the first zone.

[0005] The storage and retrieval system may further include a temperature control system configured to maintain a first air temperature in the first zone and a second air temperature in the second zone. The second air temperature may be higher than the first air temperature. This is particularly advantageous because human workers can work at a comfortable temperature in the second zone, remote from the first zone. Dry air output from the dehumidifier system may be pumped into the second zone.

[0006] The first air temperature may be between -30°C and 0°C. The first air temperature may be between -30°C and -18°C.

[0007] The second air temperature may be between -10°C and +8°C. The second air temperature may be between -10°C and 0°C, for example about -5°C.

[0008] The temperature control system may include a refrigeration system for maintaining a first air temperature in the first zone.

[0009] The temperature control system may include a heating system configured to maintain a second air temperature in the second zone.

[0010] Optionally, the dehumidifier system may include a dehumidifier unit in the first zone and a dehumidifier unit in the second zone.

[0011] The dehumidifier system may be configured to dehumidify air drawn from the second zone such that a dew point of the exhaust air is below the first air temperature.

[0012] The dehumidifier system may be configured to discharge dehumidified air into the first zone at a rate that creates a positive air pressure in the first zone relative to the second zone.

[0013] The dehumidifier system may be further configured to draw air from the passage, dehumidify the air drawn from the passage, and discharge the dehumidified air into the first zone.

[0014] The dehumidifier system can be configured to draw in and mix air from the duct and the second zone in a predetermined ratio. For example, 10% to 30% (e.g., approximately 20%) of the air drawn into the dehumidifier system can come from the duct. Accordingly, 90% to 70% (e.g., approximately 80%) of the air drawn into the dehumidifier system can come from the second zone.

[0015] The second area may be below at least a portion of the first area. The second area may be below at least a portion of the storage structure in the first area. The channel may extend vertically from its associated grid cell into the second area. The divider may be a horizontal divider (e.g., a floor).

[0016] The second region may be horizontally adjacent to the first region. The channel may extend vertically from its associated grid cell and then extend horizontally (or in a direction between vertical and horizontal) into the second region. For example, the channel may include an L-shaped channel so that the container can move vertically within the vertical portion of the channel and horizontally within the horizontal portion of the channel. The horizontal portion of the channel may extend from the vertical portion of the channel by at least the length of the storage container. The divider may be a vertical divider.

[0017] The second area may include a container station for receiving storage containers so that items can be moved into or out of each storage container. A passageway may extend from its associated grid cell to the container station so that the storage container can be moved between the storage structure and the container station via the passageway.

[0018] The channel can be at least partially defined by a chute. The chute can be formed by a vertical portion of the channel. The chute is located in the second area. The chute can extend from the divider into the second area, for example, to the container station. The channel can include a horizontal portion connected to the vertical portion of the channel. The horizontal portion includes a conveyor extending from the vertical portion to the inventory processing station. The horizontal portion can extend a distance equal to the length of at least one storage container (for example, two, three, four or five storage containers). In the context of the present invention, "length" is defined as the longest side of the storage container. Therefore, multiple storage containers can be accommodated in the channel.

[0019] The passage may include a barrier for selectively opening and closing the passage. The barrier may open and close horizontally. In particular, the barrier may open and close horizontally within a vertical portion of the passage. The barrier may open and close vertically. In particular, the barrier may open and close vertically within a horizontal portion of the passage.

[0020] The barrier may include at least one door movable between a closed configuration that prevents hot air from entering the first area from the second area and an open configuration that allows one or more storage containers to move through the passage between the first area and the second area. The at least one door may be a rolling door, a sectional door, or a tilting door.

[0021] Alternatively or additionally, the barrier may comprise an air curtain unit to provide an air curtain across the opening in the passageway.

[0022] At least a portion of the channel may be surrounded by insulation. The insulation may extend from the divider to the barrier. The barrier may be connected to the insulation on one side. The insulation may include silica aerogel.

[0023] The first area may be an enclosed area. The first area may include a floor, a plurality of walls, and a roof to define the enclosed area. The second area may be an enclosed area. The second area may include a floor, a plurality of walls, and a roof to define the enclosed area.

[0024] The storage and retrieval system may include a plurality of channels. The divider may include a plurality of openings. Each channel may extend from an associated grid cell into the second region via a corresponding opening.

[0025] The storage structure may further include a track structure located on top of the horizontal members.The track structure may further include a plurality of tracks arranged to form a grid pattern corresponding to the grid pattern formed by the horizontal members.

[0026] The storage and retrieval system may further comprise one or more load handling devices. Each load handling device may comprise: a drive assembly configured to move the load handling device on the track structure; a container retaining assembly configured to releasably retain a storage container from above; and A lifting assembly configured to raise and lower the container retaining assembly to allow the load handling device to lift and lower the storage container into and out of the storage structure and the channel via the grid cells. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a schematic side view of a storage and retrieval system including a first area and a second area.

[0028] Figure 2 is a schematic perspective view of a storage structure located within a first area, wherein containers are arranged within the storage structure and a load handling device is located on top of the storage structure.

[0029] Figure 3 is a schematic plan view of the track structure on top of the storage structure.

[0030] Figure 4 is a schematic perspective view of a load handling apparatus with the container holding assembly in position below the bottom of the load handling apparatus.

[0031] Figure 5 yes Figure 4 Schematic perspective view of a load handling apparatus, wherein the side of the outer body is omitted from view to illustrate the container receiving space.

[0032] Figure 6 yes Figure 5 Schematic perspective view of a load handling device, wherein a container occupies a container receiving space.

[0033] Figure 7 is a schematic diagram of a storage and retrieval system showing a first zone, a second zone, and a dehumidifier system.

[0034] Figure 8 is a schematic side view of a storage and retrieval system comprising Figure 1 The first and second regions of an alternative arrangement to the one shown.

[0035] Figure 9 is a schematic side view of a storage and retrieval system comprising Figure 1 The first and second regions of an alternative arrangement to the one shown.

[0036] Figure 10 (a, b, c) are schematic side views of a double door in a passage between a first area and a second area in (a) a closed configuration, (b) a partially open configuration, and (c) an open configuration.

[0037] Figure 11 (a, b, c) are schematic side views of a tilted door in a horizontal portion of a passage between a first area and a second area in (a) a closed configuration, (b) a partially open configuration, and (c) an open configuration.

[0038] Figure 12 (a, b, c) are schematic side views of a horizontally sectional door in a horizontal portion of a passage between a first area and a second area in (a) a closed configuration, (b) a partially open configuration, and (c) an open configuration. DETAILED DESCRIPTION

[0039] Figure 1A schematic side view of a storage and retrieval system for storing and retrieving frozen goods (e.g., frozen groceries) held in storage containers 9 is shown. The storage and retrieval system includes a first area 100 for storing storage containers within the storage structure 1, and a second area 200 for accessing individual storage containers that are moved out of the first area 100 and / or accessing individual storage containers that are moved into the first area 100.

[0040] Figure 2 An exemplary storage structure 1 for storing storage containers 9 in a first area 100 is shown. The storage structure 1 includes a frame comprising upright members 3 and horizontal members 5, 7 supported by the upright members 3. The horizontal members 5 extend parallel to each other and parallel to the x-axis shown. The horizontal members 7 extend parallel to each other and parallel to the y-axis shown, and extend transversely to the horizontal members 5. The upright members 3 extend parallel to each other and parallel to the z-axis shown, and extend transversely to the horizontal members 5, 7. The horizontal members 5, 7 form a grid pattern defining a plurality of grid cells 14.

[0041] The storage structure 1 defines a storage space below the horizontal members 5, 7, which includes a plurality of storage columns, each storage column being located below a corresponding grid cell 14. Each storage column can accommodate a vertical stack 11 of storage containers. Figure 1 The storage structure 1 further defines port columns below the corresponding port unit 14a. Each port column at least partially defines a passage 160 for allowing storage containers 9 to be transported between the storage structure 1 in the first area 100 and the container station 202 in the second area 200, as shown in FIG. Figure 1 shown.

[0042] Second area 200 includes one or more container stations 202. Each container station 202 is configured to receive storage containers 9 and present them individually so that items can be moved into or out of the storage containers 9. One example type of container station 202 is a picking station, at which storage containers 9 are received from storage structure 1 and customer orders are prepared by picking items from storage containers 9 and placing them into delivery containers, such as containers or bags. Another example type of container station 202 is an inventory station, at which items are placed into empty storage containers 9 for storage in storage structure 1. Other examples of container stations 202 are possible, at which storage containers 9 are received from storage structure 1 and / or moved into the storage structure. Second area 200 may include a single type of container station 202 or multiple types of container stations 202.

[0043] exist Figure 1In the example shown, the second area 200 is located directly below the overhead portion of the storage structure 1 and is separated from the first area 100 by a divider 150. More specifically, the storage and retrieval system includes a horizontal base plate 148 defining the floor of the first area 100 and the floor of the second area 200, and the divider 150 is in the form of a horizontal mezzanine floor located above the base plate 150. The main part of the storage structure 1 is supported on the base plate 148, and the overhead portion is supported on the mezzanine floor 150. The second area 200 can be further separated from the first area 100 by one or more vertical walls to define an enclosed area. The first area 100 may also include walls and a roof to define an enclosed area around the storage structure 1.

[0044] As described above, the storage and retrieval system includes one or more aisles 160 for allowing storage containers 9 to be transported between the storage structure and the container station 202. Each aisle 160 extends vertically downwardly from its associated port unit 14a via an opening 152 in the mezzanine floor 150 to the container station 202.

[0045] Each container station 202 may have one or more channels 160 leading to it. Figure 1 In the illustration, a container station 202 is shown having two aisles 160 leading to it—a discharge aisle 160a and a retrieval aisle 160b. Storage containers 9 are moved from the storage structure 1 to the container station 202 via the discharge aisle 160a, and storage containers 9 are moved from the container station 202 to the storage structure 1 via the retrieval aisle 160b. In the context of a picking station, the discharge aisle 160a can be used to drop off storage containers 9 containing products that have been ordered by customers, and the retrieval aisle 160b can be used to pick up storage containers 9 after the products have been removed from the storage containers 9, thereby returning the storage containers 9 to the storage structure 1. The container station 202 may include one or more conveyors for moving storage containers 9 between the discharge aisle 160a and the retrieval aisle 160b. Other container stations 202 may have only one aisle 160 leading to them. For example, a storage station may have only a retrieval aisle 160b leading to it, to allow storage containers 9 that have just been filled with new inventory to be moved into the storage structure 1. Other configurations of lanes 160 for each container station 202 are also possible. Each container station 202 can have one or more lanes 160 associated therewith, and each of these lanes can be a different type of lane 160, such as a discharge lane, a pickup lane, or a lane that functions as a combined discharge and pickup lane. To increase throughput, a container station 202 can have multiple lanes 160 of a specific type associated therewith.

[0046] Each channel 160 may be at least partially defined by a chute 162 (ie, a tubular structure surrounding the channel 160). Each chute 162 is preferably arranged in the second area 200, for example between the mezzanine floor 150 and the container station 202, as shown in FIG. Figure 1 As shown, it can also extend directly between the port unit 14 a and the container station 202 .

[0047] Back to Figure 2 , storage containers 9 are moved between the storage structure 1 and the container stations 202 using a load handling device 25 (hereinafter referred to as a "robot") that operates on top of the storage structure 1. In particular, the robot 25 is configured to move on tracks on top of the storage structure 1 and to lift and lower storage containers through the grid cells 14, as will now be described in further detail.

[0048] Figure 3 A large scale plan view of a portion of the track structure 13 is shown, forming Figure 1 The storage structure 1 is shown as part of the Figure 2 On top of the horizontal members 5, 7 of the storage structure 1 shown. The track structure 13 can be provided by the horizontal members 5, 7 themselves (for example, formed in or on the surface of the horizontal members 5, 7) or by one or more additional components mounted on top of the horizontal members 5, 7. The track structure 13 shown includes x-direction rails 17 and y-direction rails 19, that is, a first set of rails 17 extending in the x-direction and a second set of rails 19 extending in the y-direction transversely to the rails 17 in the first set of rails 17. The rails 17, 19 define a hole 15 in the center of the grid cell 14. The size of the hole 15 is designed to allow the storage container 9 located below the grid cell 14 to be lifted and lowered through the hole 15. The x-direction rails 17 are arranged in pairs, separated by grooves 21, and the y-direction rails 19 are arranged in pairs, separated by grooves 23. Other arrangements of the track structure are also possible. The robot 25 is provided with sets of wheels to engage corresponding x-direction or y-direction rails 17, 19 to enable the robot 25 to travel across the entire track structure 13 and reach a specific grid cell 14. The illustrated pairs of rails 17, 19, separated by grooves 21, 23, allow the robots 25 to occupy adjacent grid cells 14 (or pass each other on adjacent grid cells 14) without colliding with each other.

[0049] like Figure 4 As shown, the robot 25 includes an outer body 27 having mounted therein or thereon one or more components that enable the robot 25 to perform its intended functions. These functions may include moving across the storage structure 1 on the track structure 13 and raising or lowering the storage containers 9 via the grid cells 14 so that the robot 25 can retrieve or deposit the storage containers 9 at specific locations defined by the grid pattern.

[0050] The robot 25 shown includes a drive assembly comprising first and second sets of wheels 29, 31 mounted on an outer body 27 of the robot 25 and enabling the robot 25 to move in the x and y directions along the tracks 17 and 19, respectively. In particular, the two wheels 29 are provided at Figure 4 The wheels 29 are mounted on the shorter side of the robot 25, which is visible in FIG. 1 , while the other two wheels 29 are located on the opposite shorter side of the robot 25. The wheels 29 engage with the track 17 and are rotatably mounted on the outer body 27 of the robot 25 to allow the robot 25 to move along the track 17. Similarly, two wheels 31 are located on the outer body 27 of the robot 25. Figure 4 , and two further wheels 31 are provided on the relatively long sides of the robot 25. The wheels 31 engage with the track 19 and are rotatably mounted on the outer body 27 of the robot 25 to allow the robot 25 to move along the track 19.

[0051] To enable the robot 25 to move in the first direction and the second direction on the different wheels 29, 31, the drive assembly further includes a wheel positioning mechanism (not shown) for selectively engaging the first set of wheels 29 with the first set of tracks 17 or the second set of wheels 31 with the second set of tracks 19. The wheel positioning mechanism is configured to raise and lower the first set of wheels 29 and / or the second set of wheels 31 relative to the outer body 27, thereby enabling the load handling device 25 to be selectively moved across the tracks 17, 19 of the storage structure 1 in the first direction or the second direction.

[0052] The wheel positioning mechanism may include one or more linear actuators, rotary components, or other means for raising and lowering at least one set of wheels 29, 31 relative to the outer body 27 of the robot 25 to move at least one set of wheels 29, 31 away from and into contact with the tracks 17, 19. In some examples, only one set of wheels is configured to be raised and lowered, and the action of lowering one set of wheels may effectively lift the other set of wheels away from the corresponding tracks, while the action of raising one set of wheels may effectively lower the other set of wheels into contact with the corresponding tracks. In other examples, both sets of wheels may be raised and lowered, which advantageously means that the outer body 27 of the robot 25 remains at substantially the same height, and thus the weight of the outer body 27 and components mounted thereon does not need to be raised and lowered by the wheel positioning mechanism.

[0053] The robot 25 also includes a lifting assembly 33 and a container holding assembly 37 configured to raise and lower the storage container 9. The illustrated lifting assembly 33 includes four tethers 35 connected at their lower ends to the container holding assembly 37. The tethers 35 may be cables, ropes, belts, or any other form of tether having the necessary physical properties for lifting the storage container 9. The container holding assembly 37 includes a clamping mechanism 39 configured to engage with a feature of the storage container 9 to releasably hold the container 9 from above. In the illustrated example, the clamping mechanism 39 includes legs that can be received in corresponding holes 10 in the rim of the storage container 9 and then moved outward to engage the underside of the rim of the storage container 9. The tethers 35 can be wound upward or downward as needed to raise or lower the container holding assembly 37. One or more motors and winches or other means may be provided to achieve or control the upward or downward winding of the tethers 35.

[0054] exist Figure 5 and Figure 6 , the side of the outer body 27 of the robot 25 has been omitted from view to allow the interior of the robot 25 to be seen. The outer body 27 of the illustrated robot 25 has an upper portion 41 and a lower portion 43. The upper portion 41 is configured to accommodate or support one or more working components (not shown), such as components of the lifting assembly 33 (e.g., a motor), wireless communication components, a robot control system including one or more processors for controlling the operation of the robot 25, etc. The lower portion 43 is arranged below the upper portion 41. The lower portion 43 is open outwardly at the bottom and defines a container receiving space 45 for accommodating at least a portion of the storage container 9 that has been lifted into the container receiving space 45 by the lifting assembly 33. Figure 5 shows the container receiving space 45 before it is occupied by a storage container 9, and Figure 6 The container receiving space 45 is shown after it has been occupied by a storage container 9. The container receiving space 45 is sized so that a sufficient number of storage containers 9 can fit within the space 45 to enable the robot 25 to move across the track structure 13 on top of the storage structure 1 without the underside of the storage container 9 getting stuck on the track structure 13 or another portion of the storage structure 1. When the robot 25 has reached its intended destination, the lifting assembly 33 controls the tether 35 to lower the container holding assembly 37 and the corresponding storage container 9 out of the container receiving space 45 to the intended location. Although in the example shown, the upper portion 41 and the lower portion 43 are separated by a physical divider, in other examples, the upper portion 41 and the lower portion 43 may not be physically separated by a particular component or portion of the outer body 27 of the robot 25. The upper and lower configurations of the robot 25 allow the robot 25 to occupy only a single grid cell 14 on the track structure 13 of the storage system 1.

[0055] In an alternative example, the container receiving space 45 of the robot 25 may not be within the outer body 27 of the robot 25. For example, the container receiving space 45 may instead be adjacent to the outer body 27 of the robot 25, such as in a cantilever arrangement, with the weight of the outer body 27 of the robot 25 balancing the weight of the container 9 to be lifted. In such an embodiment, the frame or arm of the lifting assembly 33 may protrude horizontally from the outer body 27 of the robot 25, and the tether 35 may be disposed at corresponding locations on the protruding frame / arm and configured to be raised and lowered from those locations to raise and lower the storage container 9 into the container receiving space 45 adjacent to the outer body 27.

[0056] In order to transport a storage container 9 from the stack 11 in the storage structure 1 to the container station 202, the robot 25 uses its container holding assembly 37 and lifting assembly 33 to pick up the storage container 9 from the top of the stack 11, moves along the track structure 13 to the port unit 14a, lowers the storage container 9 into the channel 160 via the port unit 14a, and then releases the storage container 9 at the container station 202. In order to transport the storage container 9 from the container station 202 to the stack 11 in the storage structure 11, the operation is performed in the opposite manner, i.e., the robot 25 lowers its container holding assembly 37 into the channel 160 via the port unit 14a, picks up the storage container 9 at the container station 202, lifts the storage container 9 upward via the channel 160 and the port unit 14a, and then moves along the track structure 13 to deposit the storage container 9 on top of the stack 11.

[0057] Instead of having the robot 25 move the storage container 9 along the entire length of the aisle 160, one or more of the aisles 160 may include a container elevator for vertically transporting the storage container 9 within at least a portion of the aisle 160. For example, to transport a storage container 9 from the storage structure 1 to the container station 202, the robot 25 may lower the storage container 9 a portion of the way along the aisle 160 and release the storage container 9 onto the container elevator. The elevator may then move downward within the aisle 160 to transport the storage container 9 the remainder of the way to the container station 202. Similarly, to transport a storage container 9 from the container station 202 to the storage structure 1, the elevator may receive the storage container 9 at the container station 202 and move upward within the aisle 160 to a predetermined position along the aisle 160, from which the robot 25 may pick up the storage container 9 and lift it the remainder of the way out of the aisle 160.

[0058] Figure 7A schematic diagram of a storage and retrieval system including a first area 100, a second area 200, and a dehumidifier system 300 is shown. As previously described, the storage and retrieval system can be used to store and retrieve frozen goods. The storage and retrieval system includes a temperature control system for regulating the air temperature in the first area 100 and the second area 200. The temperature control system includes a refrigeration system 320 having one or more refrigeration units 322 with appropriate control systems and temperature sensors for maintaining the air temperature in the first area 100 at a controlled temperature (set point) suitable for frozen food, for example, below 0°C. For food safety, the controlled temperature of the first area 100 is preferably about -18°C or lower, for example, between -30°C and -18°C.

[0059] Channel 160 allows for efficient transport of storage containers 9 between first area 100 and second area 200 and, for efficiency reasons, is preferably always open, at least during working hours. This means, however, that air can flow between first area 100 and second area 200 via opening 152 in divider 150; i.e., first area 100 and second area 200 are in fluid communication via opening 152. Therefore, without any heating, the air temperature in second area 200 can reach a temperature similar to that in first area 100. Given that human workers may be present in second area 200, for example, working at container station 202, it is preferable that the air temperature in second area 200 be higher than that in first area 100 to provide a more comfortable working environment for them.

[0060] Some heating of the second area 200 may occur during operation (i.e., when the container station 202 is in operation) due to heat emitted from equipment within the second area 200 (e.g., lights, motors, etc.). Heat may also enter the second area 200 whenever any door between the second area 200 and the warmer areas of the storage and retrieval system is opened. If this heat is insufficient or cannot be relied upon to heat the second area 200 to a more comfortable operating temperature, the temperature control system may further include a heating system 330 comprising at least one heating unit 332 and a suitable control system with appropriate temperature sensors for maintaining the air temperature in the second area 200 at a specific control temperature (set point) that is higher than the control temperature in the first area 100. To balance energy efficiency and comfort, the control temperature of the second area 200 is preferably between -10°C and +8°C, preferably between -10°C and +5°C, preferably between -10°C and 0°C, and preferably around -5°C. To improve the energy efficiency of the heating system 330, the heat source is preferably derived from waste heat generated by the refrigeration system 320, or a heat pump may be used.

[0061] During operation of the storage and retrieval system, water vapor may accumulate in the second area 200. This may be due, for example, to the presence of human workers in the second area 200. Furthermore, the second area 200 may include one or more access doors to allow access between the second area 200 and other areas of the storage and retrieval system. Each time the access door is opened, humid air may enter the second area 200 from these other areas. For example, the second area 200 may be adjacent to a third area that can be operated at a temperature higher than the controlled temperature in the second area 200. For example, the third area may be operated at a temperature suitable for storing and / or handling refrigerated goods (i.e., goods that require storage at refrigerator temperatures), such as between 0°C and 8°C, preferably between 0°C and 5°C. In other examples, the third area may be operated at a temperature suitable for storing ambient goods (i.e., goods that can be safely stored at room temperature), such as between approximately 15°C and 25°C. The third area may appropriately include a refrigeration, heating, or air conditioning system to maintain the third area at a controlled temperature, depending on its intended use.

[0062] Given that there is fluid communication between the first region 100 and the second region 200 via the openings 152, the warmer, more humid air from the second region 200 will tend to flow into the cooler first region 100 via the openings 152. If the relative humidity of the air in the second region 200 is high enough, there is a risk that condensation will occur in the first region 100 due to the air temperature in the first region 100 being lower than the dew point of the air entering the first region 100 from the second region 200. Due to the freezing air temperature in the first region 100, any condensation that occurs in the first region 100 could potentially lead to unintended frost or ice formation on walls and equipment within the first region 100.

[0063] To mitigate condensation, the storage and retrieval system further includes a dehumidifier system 300. The dehumidifier system 300 includes a dehumidifier unit 302 configured to draw air from the second zone 200, dehumidify (i.e., remove moisture from) the air drawn from the second zone 200, and discharge the dehumidified air into the first zone 100. The dehumidifier system 300 may include piping configured to direct air from one or more inlets in the second zone 200 to the dehumidifier unit 302 and piping configured to direct air from the dehumidifier unit 302 to one or more outlets in the first zone 100. One or more fans may be used to draw in and exhaust the air. The inlet in the second zone 200 and the outlet in the first zone 100 may be located, for example, near the walls or ceiling of the second zone 200 and the first zone 100, respectively.

[0064] The dehumidifier unit 302 can be any suitable type of dehumidifier for operating at low temperatures (e.g., below 0°C), such as a desiccant dehumidifier. Desiccant dehumidifiers typically work by passing a moist process air stream through a desiccant material (e.g., silica gel), which absorbs moisture from the process air stream passing through it. In order to regenerate the desiccant material (i.e., remove absorbed moisture), the regeneration air stream is heated and passed through the desiccant material so that the absorbed moisture is drawn into the regeneration air stream and then discharged, for example, to the outside of a building. In order for the desiccant dehumidifier to operate continuously, the desiccant material is typically contained in a rotating wheel so that a portion of the wheel passes through the process air stream and another portion of the wheel passes through the regeneration air stream. In the case where the dehumidifier unit 302 is a desiccant dehumidifier, the regeneration air stream can be derived from a warmer area of ​​the storage and retrieval system, such as an ambient temperature area, to improve energy efficiency. The dehumidifier system 300 or the dehumidifier unit 302 itself may optionally include a cooling unit for cooling the process air (before or after the drying process), as the drying process within a desiccant dehumidifier typically results in heat being transferred to the process air vapor, which may be undesirable considering that the dehumidified air will be exhausted into the first zone 100 operating at a lower temperature.

[0065] The dehumidifier unit 302 is configured to dehumidify the air drawn in from the second zone 200 so that the dew point of the air discharged into the first zone 100 is lower than the control temperature of the first zone 100. As a safety margin, the dew point of the discharged air is preferably at least 2 to 3 degrees Celsius lower than the control temperature of the first zone 100. Given that the refrigeration unit 322 of the refrigeration system 320 can output air slightly cooler than the control temperature in the first zone 100 to maintain the air temperature at the set point, the dew point of the discharged air is preferably lower than the temperature of the air output by the refrigeration unit 322 to minimize the risk of ice formation on and near the refrigeration unit 322. Therefore, as a further safety margin, the dew point of the discharged air is preferably at least 2 to 3 degrees Celsius lower than the temperature of the air output from the refrigeration unit 320. The temperature of the air output from the refrigeration unit 322 can be measured using a temperature sensor or can be assumed to be a static, expected value.

[0066] To dehumidify the air drawn in from the second zone 200 to a specific dew point, the dehumidifier system 300 includes a control system that includes a humidity sensor (e.g., a capacitive or resistive humidity sensor) for measuring relative humidity and a temperature sensor for measuring air temperature. The control system further includes a controller that calculates the dew point based on these measurements using a known equation relating dew point, relative humidity, and temperature (e.g., the Magnus equation or the Arden-Buck equation). The controller can then control the operation of the dehumidifier unit 302 (i.e., control parameters of the dehumidifier unit 302 to increase or decrease moisture absorption) to maintain the dew point of the exhaust air at a specific set point. The control system can alternatively be configured to control the operation of the dehumidifier unit 302 to maintain the relative humidity of the exhaust air at a specific set point that will result in a dew point below the control temperature of the first zone 100 (based on a previously performed calculation).

[0067] The air flow rate of the dehumidifier unit 302 (i.e., the rate at which air is drawn into and exhausted from the dehumidifier unit 302) is preferably high enough to overcome the air vapor pressure of the air in the second zone 200 so that the flow of air from the second zone 200 into the first zone 100 through the openings 152 is minimized. In other words, the dehumidifier air flow rate is preferably high enough to create a positive pressure in the first zone 100 relative to the second zone 200 to substantially prevent air from flowing from the second zone 200 into the first zone 100 through the openings 152. The required air flow rate can be determined by calculating the theoretical flow rate from the second zone 200 to the first zone 100 through the openings 152 due to the temperature difference between the first zone 100 and the second zone 200. This rate can be calculated or estimated based on the total area of ​​the openings 152 between the first zone 100 and the second zone 200 (i.e., the total number of openings 152 multiplied by the area of ​​each opening 152) and the air velocity value as a function of the temperature difference between the two zones.

[0068] In order to provide a sufficiently high air flow rate and / or provide redundancy in the event of a dehumidifier unit failure, the dehumidifier system 300 may include a plurality of dehumidifier units 302, which are configured to draw air from the second zone 200, dehumidify the air drawn from the second zone 200, and discharge the dehumidified air to the first zone 100.

[0069] In addition to drawing air from the second zone 200, the dehumidifier unit 302 can be further configured to draw air from the duct 160, for example, near the opening 152. Drawing air from the duct 160 can help increase the positive pressure in the first zone 100, further minimizing the risk of air entering the first zone from the second zone 200 via the opening 152. The duct 160 is also the closest point at which air from the second zone 200 can enter the first zone 100, so drawing air from the duct 160 further reduces the risk of air ingress. The dehumidifier system 300 can include piping arranged to direct air from each duct 160 to the dehumidifier unit 302. For example, each chute defining the duct 160 can include a cutout, and piping can be connected to the chute 162 at the cutout. The dehumidifier system 300 is preferably configured to mix air from the second zone 200 with air from the duct 160 and draw the mixed air through the dehumidifier unit 302. The dehumidifier system 300 can draw air from the duct 160 and draw air from the second zone 200 at a predetermined ratio. The ratio of the mixed air drawn from the duct 160 is preferably between 10% and 30%, for example, approximately 20%. The dehumidifier system 300 can include an air damper 304 (e.g., a volume control damper) to control the ratio of the air drawn from the duct 160 and the second zone 200 so that the air is mixed according to the predetermined ratio. In the case where the dehumidifier system 300 includes a plurality of dehumidifier units 302, each dehumidifier unit 302 can be configured to draw air from a subset of the duct 160 and dehumidify it.

[0070] Each channel 160 may also include a barrier 164 for selectively blocking and opening the channel 160, such that when the barrier 164 is closed, air flow through the channel 160 is reduced or substantially blocked. The barrier 164 may include any suitable mechanism for allowing it to be selectively opened and closed, such as a hinge or sliding mechanism, and may be manually operated or automatically operated using an actuator and controller. Figure 10 The example of the barrier 164 shown in (a to c) includes at least one door that is rotatable between a closed configuration to prevent cold air from the first area 100 from entering the second area 200 (see FIG. Figure 10 a), the open configuration allows one or more storage containers to move through the passage when moving between the first area 100 and the second area 200 (see Figure 10b). An actuator known in the art, such as a linear solenoid, may be used to rotate the at least one door between an open configuration and a closed configuration. In a particular embodiment of the invention, the at least one door comprises two doors or a double door or two blades 166, wherein one of the blades rotates in a clockwise direction and the other rotates in a counter-clockwise direction to move the double door between the open configuration and the closed configuration. The at least one door comprises suitable insulation to prevent or at least limit the transfer of heat from the second area to the first area when the at least one door is in the closed configuration. For example, the door may comprise an insulating sheath. In Figure 10 In the particular example shown in (a to c), each of the two blades includes an upper side and a lower side. The upper side of each blade includes an insulator 168. The lower side of each blade includes a tote guide 170 so that when at least one door is in the position shown in FIG. Figure 10 In the open configuration shown in FIG. 3 , i.e., in a generally vertical orientation, the underside of the door serves to guide the storage container 9 through the passage 160. Figure 10 In the particular embodiment shown in Figure c, double doors 164 are used to enable storage containers to move up and / or down the passageway between the first area 100 and the second area 200. To guide the storage containers when the double doors are in the open configuration, the undersides of the doors include 90° guide plates that mate with the corners of the storage containers. Barrier 164 can also be a completely separate object that can be manually inserted into and removed from passageway 160 to substantially block and open passageway 160, respectively. Barrier 164 can comprise an insulating material, such as polymer foam. Barrier 164 can be located in the second area 200, for example, at or near the end of passageway 160 where it enters container station 202. The purpose of barrier 164 is to help prevent cold air from the first area 100 from entering the second area via passageway 160 when the second area 200 is not in operation, i.e., when container station 202 is not in operation, such as during system shutdown. This is particularly important when container station 202 in the second area 200 is not in operation, such as at night. Thus, heat loss from the second zone 200 during non-operating periods can be minimized, which helps minimize the energy cost of the heating system 330 for maintaining the second zone 200 at its controlled temperature when the second zone 200 is not operating or for raising the second zone 200 to temperature when the heating system 330 is closed during non-operating periods.

[0071] Figure 10 The barriers shown in (a to c) open and close horizontally. However, the barriers can also open and close vertically, as in Figure 11 (a to c) and Figure 12 (a to c) are shown. Figure 11 (a to c) and Figure 12In (a to c), the barrier 164 is positioned within the horizontal portion of the channel 160. If one or more conveyors 182 are present within the horizontal portion of the channel 160, such as Figure 11 (a to c) and Figure 12 As shown in (a to c), when the barrier 164 is in the closed configuration, the barrier 164 is positioned between adjacent conveyors. Alternatively, when the barrier 164 is in the closed configuration, the base of the barrier 164 can rest on the conveyor 182.

[0072] Figure 11 (a to c) and Figure 12 Each barrier in (a to c) comprises a single door or door assembly 180, 190 that opens vertically. The single door or door assembly 180, 190 can be in a closed configuration (see Figure 11 (a) and Figure 12 (a)) and the open configuration (see Figure 11 (c) and Figure 12 (c)) between the first area 100 and the second area 200, the closed configuration prevents cold air from the first area 100 from entering the second area 200, and the open configuration allows one or more storage containers to move (horizontally) through the passage 160 when moving between the first area 100 and the second area 200. In the open configuration, the doors 180, 190 are positioned so that they extend in a direction perpendicular to the direction in which the doors extend when in the closed position. In other words, when the doors are in the open configuration, the doors 180, 190 are positioned horizontally at the top of the passage 160 to allow one or more storage containers to move under the open doors and pass through the passage 160 when moving between the first area 100 and the second area 200.

[0073] Figure 11 (a to c) show a barrier 164 including an up and down tilted door 180. The door 180 is positioned within a door frame 181. The door frame may include an insulating material, for example, one side of the door frame may include silica aerogel. When the door is in the closed configuration, the door frame 181 extends along the top of the door 180 and along the vertical sides of the door 180, as shown in FIG. Figure 11 (a). The door 180 moves along a pair of horizontal guides 183. The movement of the door can be facilitated by an elastic member. Figure 11 In (a to c), the elastic members are two extension springs 184, which are stretched to their maximum length when the door 180 is in the closed configuration, as shown in FIG. Figure 11(a). The bottom of the tension spring 184 remains stationary, and the top of the spring is each fixed to one of two lever arms 186. Each lever arm 186 is connected to the door 180 by a connector 188 to allow the lever arm 186 to pivot about the connector at or near the bottom of the door 180. As the door is activated to open, a motor (not shown) cycles the belt drive 189. An arm 185 is attached at one end to the top of the door 180 and to the drive belt 189 at the opposite end so that when the drive belt cycles, the arm 185 moves to pull the door 180 into the open configuration (as shown in FIG. Figure 11 (c)), and the extension spring 184 contracts and helps lift the weight of the door. Conversely, if the drive belt circulates in the opposite direction, the arm 185 moves to push the door 180 into the closed configuration (as shown in FIG. Figure 11 (a)), and the tension spring 184 is driven to stretch. Figure 11 As shown in (b), when the door 180 is moved to the closed configuration or the open configuration, the door tilts up and down in a diagonal motion. Although extension springs are useful in lifting the weight of the door because the springs are biased toward the open configuration, it is not necessary to have springs if the motor has enough power to overcome the weight of the door.

[0074] Figure 12 The barrier 164 in (a to c) comprises a rolling door. In particular, Figure 12 The rolling shutter door (a to c) is a horizontal segmented or segmented door 190 that opens and closes vertically. The door 190 is positioned within a door frame 181. The door frame may include an insulating material, for example, one side of the door frame may include silica aerogel. When the door is in the closed configuration, the door frame 181 extends along the top of the door 190 and along the vertical sides of the door 190, as shown in FIG. Figure 12 (a) is shown. Figure 12 Seven segments 192 are shown in the door 190 of (a to c), but there may be 3 to 5 segments, or 6 to 8 segments, or 9 to 12 segments, or more than 13 segments. Linear bearings (not shown) are attached to the segments 192 and allow the bearings to run along one or more guides 183. Figure 12 In the embodiment, one or more guides are a single guide including a vertical portion, a horizontal portion 194, and a curved portion 187, but the sections of the guide may be provided as separate guides. The curved portion 187 is positioned between the vertical portion and the horizontal portion 194 to allow the sectional door 190 to be oriented from a vertical orientation (e.g., Figure 12 (a)) to a horizontal orientation (as shown in Figure 12 (c) and vice versa. Figure 12 (a) shows the door in its closed configuration, and Figure 12(b) shows the door in a partially open configuration, whereby a portion of the section 192 has moved into the horizontal portion 194 of the guide 183. The radius of curvature of the door 190 when undergoing a change in orientation or direction is determined by the section size and configuration of the section 192. A high radius of curvature requires a smaller section size, while a low radius of curvature can be achieved with a larger section size. In order to move the door 190 from a closed configuration (e.g. Figure 12 (a)) moves to the open configuration (as shown in Figure 12 (c)), a motor (not shown) circulates the belt drive 189. The arm 185 is attached to the top of the door 190 at one end, and the opposite end of the arm 185 is connected to the drive belt 189 so that when the drive belt 189 rotates in one direction, the arm 185 moves to pull the door 190 upward along the guide 183 so that the door 190 gradually moves into the horizontal portion of the guide (as shown in FIG. Figure 12 (b)), and then into the open configuration (as Figure 12 (c)). Conversely, if the drive belt 189 circulates in the opposite direction, the arm 185 moves to push the door 190 into the closed configuration (as shown in FIG. Figure 12 (a)). Instead of moving the door 190 into the horizontal portion of the guide 183, the door 190 may alternatively be wound on a reel at the top of the channel.

[0075] Figure 11 and Figure 12 The belt drive 189 in the embodiment comprises a rubber belt, preferably a steel reinforced rubber belt. Alternatively, a chain belt may be used. Figure 11 and Figure 12 The doors 180, 190 can be driven by a rotary motor, a gear screw, a stepper motor, a linear motor, a DC or AC motor. The motor can be mounted directly on the door or mounted at the top or bottom of the channel 160. The door can be locked in the closed or open configuration by a ejection bolt, an electromagnet, an electric clutch, or any other known mechanism.

[0076] As an alternative to or in addition to at least one door, the barrier 164 may include an air curtain unit (not shown) that generates an air flow across the passage 160 to create an air door. The air curtain unit may be arranged in the passage 160, the passage 160 having an inlet extending into the passage for drawing cool air from the first area or the second area and an outlet including a mouth, the mouth being configured to guide the cool air through the passage 160 to form a seal or air curtain across the passage. The air curtain separates the different temperature environments of the first area 100 and the second area 200, while allowing storage containers to flow smoothly and uninterruptedly up and / or down the passage 160. Similar to a physical door, the air curtain also prevents cool air from the first area 100 from entering the second area 200. One advantage of using an air curtain over a door that opens physically is that fewer moving parts are required, reducing the risk of mechanical failure. Another advantage of using an air curtain is that it is more time-saving because there is no need to wait for a physical door to open or close.

[0077] Each channel 160 can also be insulated along at least a portion of its length. For example, each channel 160 can be insulated along a portion within the second region 200. Where the channels 160 are defined by chutes 162, the walls of the chutes 162 can be coated with an insulating material (e.g., polymer foam), or the walls themselves can be made of an insulating material. Where each channel 160 includes a barrier 164, the chutes 162 can be insulated from the divider 150 up to the location of the barrier 164 to further help prevent cold air from leaking from the first region 100 into the second region 200 during non-operational periods. The insulation can also help prevent humid air in the second region 200 from condensing on the outside of the chutes 162 because, without insulation, due to the proximity of the chutes 162 to the first region 100, the temperature outside of the chutes 162 can be similar to the temperature of the air in the first region 100, and therefore can be below the dew point of the air in the second region 200.

[0078] The divider 150 and / or any other wall separating the second region 200 from the first region 100 may also include insulating material to further insulate the second region 200 from the first region 100 , thereby reducing the energy costs of the heating system 330 .

[0079] Thus, the above-described storage and retrieval system helps overcome issues associated with the storage and retrieval of frozen goods, where a freezing temperature zone (first region 100) is in fluid communication with a warmer, potentially more humid region (second region 200). In particular, by discharging dehumidified air into the first region 100, the first region 100 can be kept sufficiently dry to minimize the risk of frost and ice formation. Furthermore, by drawing air from the second region 200 and passages 160 and discharging it into the first region 100, a positive pressure can be generated in the first region 100, reducing the risk of humid air entering the first region 100 from the second region 200. Furthermore, the dehumidified air discharged into the first region 100 will also be circulated back into the second region 200 via openings 152, thereby lowering the relative humidity in the second region 200 and reducing the risk of condensation therein. As a result of these effects, the second region 200 can be maintained at a warmer temperature than the first region 100, providing a more comfortable working environment for human workers.

[0080] The present invention is not limited to the precise forms described above, and various modifications and variations falling within the scope of the claims will be apparent to those skilled in the art.

[0081] For example, instead of the second area 200 being located below only a portion of the storage structure 1 via the use of a mezzanine floor 150, the second area 200 may be located at a level lower than the entire storage structure 1, such as Figure 8 In other words, the partition 150 may be located between the entire storage structure 1 and the second area 200 .

[0082] Additionally, the channel 160 need not extend vertically all the way to the container station 202. The channel may extend downward to a location away from the container station 202 and then be transported to the container station 202 in a different direction (eg, horizontally), such as via a conveyor.

[0083] The second area 200 also does not need to be below the first area 100. Instead, the second area 200 can be adjacent to the first area 100 in a horizontal direction. In this case, the partition 150 separating the first area 100 and the second area 200 can be a vertical wall rather than a floor, and the channel can initially extend downward from the port unit 14a and then extend horizontally to the second area 200 via the opening 152 in the partition 150. Each channel can include a conveyor that transports the storage containers 9 along the horizontal portion of the channel 160. Figure 9 An example of such an arrangement is shown in .

Claims

1. A storage and retrieval system comprising: The first area includes a storage structure, and the storage structure includes: a plurality of horizontal members arranged to form a grid pattern defining a plurality of grid cells; a plurality of upright members configured to support the horizontal members from below to define a storage area below the grid cells for storing stacks of storage containers; a second region separated from the first region by a partition, wherein the partition includes an opening to allow fluid communication between the first region and the second region; a channel extending from an associated grid cell of the storage structure through the opening in the divider into the second region so that storage containers can be moved between the first region and the second region via the channel; and A dehumidifier system is configured to draw in air from the second zone, dehumidify the air, and discharge the dehumidified air into the first zone.

2. The storage and retrieval system of claim 1 , further comprising a temperature control system configured to maintain a first air temperature in the first area and a second air temperature in the second area, wherein the second air temperature is higher than the first air temperature.

3. The storage and retrieval system of claim 2, wherein: The first air temperature is between -30°C and 0°C.

4. The storage and retrieval system of claim 3, wherein: The first air temperature is between -30°C and -18°C.

5. A storage and retrieval system according to any one of claims 2 to 4, wherein: The second air temperature is between -10°C and +8°C.

6. The storage and retrieval system of claim 5, wherein: The second air temperature is between -10°C and 0°C.

7. A storage and retrieval system according to any one of claims 2 to 6, wherein: The temperature control system includes a refrigeration system for maintaining the first air temperature in the first zone.

8. A storage and retrieval system according to any one of claims 2 to 7, wherein: The temperature control system includes a heating system configured to maintain the second air temperature in the second zone.

9. The storage system according to any one of claims 2 to 8, wherein: The dehumidifier system is configured to dehumidify air drawn from the second zone such that a dew point of the exhaust air is below the first air temperature.

10. The storage system according to any one of claims 2 to 9, wherein: The dehumidifier system is configured to discharge the dehumidified air into the first zone at a rate that creates a positive air pressure in the first zone relative to the second zone.

11. A storage system according to any one of the preceding claims, wherein: The dehumidifier system is further configured to draw air from the passage, dehumidify the air drawn from the passage, and discharge the dehumidified air into the first zone.

12. The storage system according to claim 11, wherein: The dehumidifier system is configured to draw and mix the air from the passage and the second zone in a predetermined ratio.

13. The storage system according to claim 12, wherein: 10% to 30% of the air drawn in by the dehumidifier system comes from the duct.

14. A storage and retrieval system according to any one of the preceding claims, wherein: The second region is below at least a portion of the first region, and the channels extend vertically from their associated grid cells into the second region.

15. A storage and retrieval system according to any one of the preceding claims, wherein: The second area includes a container station for receiving storage containers so that items can be moved into or out of each storage container, and wherein the channel extends from its associated grid cell to the container station so that storage containers can be moved between the storage structure and the container station via the channel.

16. A storage and retrieval system according to any one of the preceding claims, wherein: The channel includes a barrier for selectively opening and closing the channel.

17. The storage and retrieval system of claim 16, wherein: The barrier includes at least one door.

18. The storage and retrieval system of claim 17, wherein: The at least one door is a tilting door.

19. The storage and retrieval system of claim 17, wherein: The at least one door is a rolling door.

20. The storage and retrieval system of any one of claims 16 to 19, wherein the barrier comprises an air curtain unit configured to provide an air curtain across the opening in the passageway.

21. The storage and retrieval system of any preceding claim, wherein at least a portion of the channel is surrounded by insulating material.

22. A storage and retrieval system according to any one of the preceding claims, wherein: The storage and retrieval system includes a plurality of channels, and the divider includes a plurality of openings, wherein each channel extends from an associated grid cell through a respective opening into the second region.

23. A storage and retrieval system according to any one of the preceding claims, wherein: The storage structure further comprises a track structure located on top of the horizontal members, wherein the track structure comprises a plurality of tracks arranged to form a grid pattern corresponding to the grid pattern formed by the horizontal members; and the storage and retrieval system further comprises one or more load handling devices, each load handling device comprising: a drive assembly configured to move the load handling device on the track structure; a container retaining assembly configured to releasably retain a storage container from above; and A lifting assembly is configured to raise and lower the container holding assembly to allow the load handling device to lift and lower storage containers into and out of the storage structure and the passageway via the grid cells.

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