Article handling system and robotic load handling apparatus

Abstract

The present invention relates to an article handling system and a robotic load handling apparatus wherein the article handling system comprises: two sets of substantially vertical tracks forming a grid above a stack of several containers; containers of different heights within the stack; at least one robotic load handling device operable on the grid, the robotic load handling device comprising a body mounted on a wheel, the wheels comprise a first set of wheels arranged to engage with at least two tracks of the first set of tracks and a second set of wheels arranged to engage with at least two tracks of the second set of tracks, the first set of wheels being independently movable and drivable relative to the second set of wheels such that when moving, only one set of wheels engage with the grid at any time; the robotic load handling device is configured to lift and move containers of different heights.

Description

[0001] This application is a divisional application of Chinese invention patent application No. 201580044136.5, filed on June 24, 2015, entitled "Robot Article Handling System, Apparatus and Method", filed by the same applicant. Technical Field

[0002] This invention relates to a robotic article handling system, apparatus, and method, and more particularly, but not limited to, a series of robotic devices used in a robotic article handling system, and methods for expanding the types of goods that can be handled in such a system. Background Technology

[0003] This application claims priority to UK Patent Application No. GB1506364.7, filed on 15 April 2015, and UK Patent Application No. GB1411254.4, filed on 25 June 2014, the contents of which are incorporated herein by reference.

[0004] Some commercial and industrial activities require systems capable of storing and retrieving large quantities of different products. One known system for storing and retrieving goods across multiple product lines involves stacking storage boxes or containers one on top of another into rows. Storage boxes or containers are accessed from above, eliminating the need for aisles between rows of containers and allowing for the storage of more containers within a given space.

[0005] Methods for handling rows of stacked containers are well understood. Some such systems, such as those described in inventor Bettel's US2701065, involve stacks of individual containers arranged in rows to reduce the storage volume associated with storing such containers, while still allowing access to specific containers as needed. Access to a specific container can be achieved by providing a relatively sophisticated lifting mechanism that can be used to stack and move specific containers from the stack. However, in many cases, such systems are impractical in terms of cost, and most of these systems are already commercialized for storing and handling large shipping containers.

[0006] Solutions have been developed that utilize independent container stacks and provide mechanisms for retrieving and storing dedicated containers, such as those described in Cimcorp's EP0767113B. Cimcorp discloses a mechanism for moving several stacked containers using a rectangular tube robotic load handler, which can be lowered around the container stack and configured to grasp a container from any layer of the stack. This allows several containers to be lifted simultaneously from a single stack. Movable rectangular tubes can be used to move several containers from the top of one stack to the top of another, or from one stack to an external location and vice versa. Such systems are particularly useful when all containers in a single stack contain the same product (also known as a single-item stack).

[0007] In a system as described in '113, the height of the rectangular tube must be at least the same as the height of the largest container stack in order to retrieve the highest container stack in a single operation. Therefore, when used in enclosed spaces such as warehouses, the maximum height of the stack is limited by the need to accommodate the rectangular tube of the load processor.

[0008] EP1037828B1 (Autostore) describes a system for stacking containers within a frame structure, the contents of which are incorporated herein by reference. A schematic diagram illustrating such a system is attached. Figure 1-4 As shown, the robotic load handling equipment can move controllably around the stack on a track system on the uppermost surface of the stack.

[0009] Norwegian Patent No. 317366 further describes one form of the robotic load handling device, the contents of which are incorporated herein by reference. Figures 3(a) and 3(b) are perspective views of the rear and front of the load handling device, respectively, and Figure 3(c) is a perspective view of the front of the load handling device for the lifting box.

[0010] UK Patent Application No. GB1413155.1, filed on July 24, 2014, describes a further development of load handling equipment in which each robotic load handler occupies only one grid space, thus allowing for higher density of load handlers and thus higher throughput for a given size system.

[0011] A major drawback of existing systems is their limitation to containers with a specified footprint. Furthermore, the height of the container is typically restricted by the design of the robotic load handler. This generally confines such systems to items that fit within the container. In typical applications, this means that 1-10% of the total volume requires different handling methods, often manually. This results in increased system complexity, low productivity, and inefficient space utilization. The present invention addresses these problems by providing a solution for small quantities of larger products integrated within a system primarily designed for large volumes of smaller goods.

[0012] In typical retail or parcel handling scenarios, the above-described system can handle most, but not all, products or parcels. Ideally, for most products, a standard container of approximately 600×400×350mm (length×width×height) is used, as this size typically holds 90-99% of all products and is small enough to be handled manually when needed. This size container is also small enough to provide a very large number of containers within a given building size, thus facilitating the handling of very large quantities of different products. In some cases with existing systems, normal-height containers and shorter containers can also be used in combination. The aim is to increase the number of containers in a given-size system, which is advantageous under certain conditions. Summary of the Invention

[0013] According to the present invention, an article handling system is provided, comprising two sets of substantially perpendicular tracks forming a grid above several stacked containers, a portion of the stack including a box having a larger cross-sectional area than containers in the remainder of the stack. The handling system further includes several robotic load handling devices operating on the grid above the stacked containers. Each load handling device includes a body mounted on wheels, a first set of wheels configured to engage at least two tracks of the first set of tracks, and a second set of wheels configured to engage at least two tracks of the second set of tracks. The first set of wheels is independently movable and actuated relative to the second set of wheels, such that during movement, only one set of wheels is engaged with the grid at any given time, thereby enabling the load handling device to move along the tracks to any point on the grid by only actuating that set of wheels to engage with the tracks. At least one robotic handling device operable on the grid is sized to lift and move containers from within a portion of the stack containing large containers.

[0014] According to the present invention, a robotic load handling device is also provided, comprising a body having a chamber, the body including two sets of wheels mounted on a vertical side of the body, each set of wheels being independently retractable and actuated relative to the other set of wheels, the chamber in the body being sized to accept containers from an item picking system, the item handling system including a grid disposed above a plurality of container stacks, the chamber in the body being sized to accept containers having a cross-sectional area defined by an integer number of grid intervals in the item handling system.

[0015] In this way, the height of the container is no longer limited by the size of the robot's load handling unit. With taller containers, such as 600×400×800mm, many items that cannot fit into normal containers can be handled. Attached Figure Description

[0016] The invention will now be described with reference to the accompanying drawings, in which: Appendix Figure 1 It is a three-dimensional schematic diagram of a frame structure for storing several boxes stacked in a known storage system; Appendix Figure 2 It is attached Figure 1 A plan view of a portion of the frame structure shown; Figures 3(a) and 3(b) are respectively related to Figure 1 and Figure 2 The following are rear and front perspective perspectives of a robot load handling device used together with the frame structure shown. Figure 3(c) is a perspective perspective of a known load handling device for a lifting box in use. Appendix Figure 4 This is a three-dimensional schematic diagram of a known storage system, which includes the storage system located in the attached... Figure 1 and 2 The frame structure shown includes several load processing devices of the type illustrated in Figures 3(a), 3(b), and 3(c); Appendix Figure 5 This is a three-dimensional schematic diagram of a known storage system, which includes the storage system located in the attached... Figure 1 and 2 The frame structure shown in Figures 3(a), 3(b) and 3(c) contains several load processing devices of the type shown in Figures 3(a), 3(b) and 3(c), and the frame structure comprises boxes of different sizes. Appendix Figure 6a This is a 3D diagram of a normal box, with attached. Figure 6b It is a perspective view of tall boxes of different sizes capable of carrying large-sized goods moved by a load handling machine of one form of the present invention; Appendix Figure 7 According to one form of the invention, it is capable of being transported as attached. Figure 6b A schematic diagram of the load handling equipment for the box shown; Appendix Figure 8 As attached Figure 7 The diagram shows a three-dimensional illustration of a load processing device that can operate on a grid, mixed with load processing devices of normal size, the stack comprising normal-sized boxes and tall boxes; Appendix Figure 9 In the attached Figure 1 and 2 The diagram shows a second form of the load processing device of the present invention operating on a grid, which is larger than the normal load processing device in all dimensions (shown for comparison). Appendix Figure 10 This is a schematic diagram of selecting a large container of a different size from a normal box, which can be stored in the stack for removal by a load handling device according to other forms of the invention; Appendix Figure 11 This is a schematic diagram of a large-load processing device for lifting large containers according to a third embodiment of the present invention; Appendix Figure 12 This is a schematic diagram of a heavy load handling device for lifting large boxes from stacks of different heights, according to a form of the present invention. Appendix Figure 13 It is a schematic diagram of a grid system with large box areas and some stations with large boxes, as well as areas and stations containing only normal-sized boxes and load processing equipment. Detailed Implementation

[0017] As attached Figure 1 and 2 As shown, stackable containers, i.e., boxes 10, are stacked one on top of the other to form a stack 12. The stacks 12 are placed within a grid frame structure 14 in a warehouse or production environment. (See attached image) Figure 1 This is a three-dimensional schematic diagram of the frame structure 14, with attached... Figure 2 This is a top view of the stack 12 of boxes 10 arranged in the frame structure 14. Each box 10 generally contains several products (not shown in the figure). The products in each box 10 can be the same type of product or different types of products, depending on the actual situation.

[0018] The frame structure 14 includes several vertical members 16 supporting the horizontal members 18 and 20. A first set of parallel horizontal members 18 is perpendicular to a second set of parallel horizontal members 20, forming several horizontal grid structures supported by the vertical members 16. The members 16, 18, and 20 are typically made of metal. The boxes 10 are stacked between the members 16, 18, and 20 of the frame structure 14 so that the frame structure 14 can prevent horizontal movement of the stack 12 formed by the boxes 10 and control the vertical movement of the boxes 10.

[0019] The top layer of the frame structure 14 includes a grid-like track 22 that traverses the top of the stack 12. As shown in Figures 3 and 4, the track 22 supports several robotic load-handling devices 30. A first set 22a of parallel tracks 22 guides the load-handling devices 30 to move along a first direction (X-axis direction) through the top of the frame structure 14. A second set 22b of parallel tracks 22 is perpendicular to the first set 22a and guides the load-handling devices 30 to move along a second direction (Y-axis direction) perpendicular to the first direction. Thus, the load-handling devices 30 can move along the track 22 in two directions within the XY two-dimensional plane, allowing them to move to a position above any of the stacks 12.

[0020] Each load handling device 30 includes a transport vehicle 32 for sliding along the X-axis and Y-axis directions on the tracks 22 on the frame structure 14 above the stack 12. A first set of wheels 34 includes a pair of wheels 34 on the front of the transport vehicle 32 and a pair of wheels 34 on the rear of the transport vehicle 32 for engaging with two adjacent tracks of the first set 22a of the tracks 22. Similarly, a second set of wheels 36 includes a pair of wheels 36 on each side of the transport vehicle 32 for engaging with two adjacent tracks of the second set 22b of the tracks 22. Each set of wheels 34, 36 can be raised or lowered, allowing either the first set of wheels 34 or the second set of wheels 36 to engage with the tracks 22a and 22b respectively at any time.

[0021] When the first set of wheels 34 engages with the first set of tracks 22a, the second set of wheels 36 rises and disengages from the tracks 22. The wheels 34 are driven by a transmission mechanism (not shown) built into the vehicle 32, moving the load handling device 30 along the X-axis. To move the load handling device 30 along the Y-axis, the first set of wheels 34 rises and disengages from the tracks 22, while the second set of wheels 36 lowers and engages with the second set of tracks 22a. The transmission mechanism can then be used to drive the second set of wheels 36 to move along the Y-axis.

[0022] In this way, one or more robotic load handling devices 30 can move around on the top surface of the stack 12 on the frame structure 14 under the control of a central picking system (not shown). Each robotic load handling device 30 has tools for lifting one or more boxes or containers from the stack to access the desired product. Thus, multiple products can be accessed from multiple locations in the grid and stack at any time.

[0023] As can be seen from the above description and with reference to the accompanying drawings, a portion of the load handling device 30, carried by wheels, covers one grid interval of the grid system above the stack.

[0024] Appendix Figure 4 A typical storage system as described above is shown, which has several load processing devices 30 operating on a stack 12.

[0025] In a first embodiment of the invention, a high robot load processor is used. A high robot load processor device 50 will now be described with reference to Figures 6 to 8. Figures 1 to 5 All items shared by the described load processing equipment will use the same label.

[0026] These higher-load processing units are designed to be carried in boxes similar in size to those shown in Figure 6. Figure 7 A high-load handling device for lifting tall boxes is demonstrated. When lifting the box to the top of the stack, the box is located within the main body of the load handling device. The load handling device 50 maintains the same dimensions as a normal load handling device because its wheeled portion occupies one grid interval of the track system above the stacked boxes. In this way, the stack can contain boxes of varying heights, and the high-load handling device, moved to the grid interval, removes the tall boxes as needed. The device for normal-height boxes can then continue removing boxes of normal height as required.

[0027] Appendix Figure 8 Multiple high-load processing units capable of operating on a grid above a stack, as well as multiple standard-sized load processing units, are demonstrated. It should be noted that the stack contains boxes of varying heights. However, the space occupied by all the boxes within the stack is the area occupied by a single grid interval.

[0028] It should be understood that these higher load processors may have poorer mechanical stability compared to normal robotic load processors, but this is acceptable if acceleration and speed are appropriately reduced.

[0029] For larger items, another embodiment of the invention provides a solution for a robotic load handler spanning more than one grid space. This can be, for example, 2, 4, 6, 8, or 9 grid spaces, represented as 2×1, 1×2, 2×2, 2×3, 4×2, 2×4, or 3×3 grid spaces. In the examples below, only the case of a load handling device occupying an area of ​​2×2 spaces will be described. However, it should be understood that the larger load handling device can occupy any number of grid intervals. To fully utilize the integrated system for both normal and larger robotic load handlers, these large load handling devices 50a will be designed to travel on the same grid structure as the normal load handler, as shown in the attached diagram. Figure 9 As shown.

[0030] High-load processing equipment can be equipped with multiple sets of wheels, 34 or 36.

[0031] As attached Figure 9 As shown, a load handling device with a larger 2×2 grid spacing can operate on the grid of a load handling device with the same area occupied by other normal single grid spacing devices. The 2×2 load handling device 50a is provided with a first set of wheels 34, comprising multiple pairs of wheels 34 on opposite parallel sides of the transport vehicle 50a. The wheels 34 are configured to engage with three adjacent tracks of a first set 22a of tracks 22.

[0032] Similarly, a second set of paired wheels 36 is provided, comprising pairs of wheels 36 on opposite sides of the vehicle, these opposite sides being substantially perpendicular to the first set of opposite sides of the vehicle. The wheels 36 are configured to engage with two adjacent tracks of the second set 22b of the track 22.

[0033] Each set of wheels 34 and 36 can be raised or lowered, so that the first set of wheels 34 or the second set of wheels 36 can engage with the corresponding track sets 22a and 22b at any time.

[0034] As attached Figure 9 As shown, high-load processing devices can operate on the same grid as normal-load processing devices. However, in the attached... Figure 9 In this process, the device will lift multiple containers with a single grid spacing size.

[0035] As attached Figure 11 As shown, in use, the large-load handling equipment can lift containers of approximately 1300 × 900 mm, assuming a normal container of 600 × 400 mm located in a single grid interval, and a stacking spacing of 100 mm. These 2 × 2 grid interval containers can have different heights to accommodate products of different sizes. For example, the heights of these large containers can be 300 mm, 500 mm, and 1000 mm, as shown in the attached figure. Figure 10 As shown.

[0036] Appendix Figure 10 The larger 2×2 grid-spaced boxes shown cannot be stacked in a stack of boxes with smaller 1×1 grid spacing. Conversely, a normal 1×1 grid-spaced load handling unit cannot pass through the space above a stack of large containers. A typical system according to this embodiment of the invention would have most of the facilities dedicated to normal containers and normal robotic load handling units. There would be a small number of workstations for receiving, picking / packaging, and dispatching goods for larger containers, and a relatively small portion of storage space dedicated to large containers and the corresponding grid above them. (See Appendix) Figure 12 and 13 This arrangement was shown.

[0037] In use, the large robotic load handling equipment operates normally on the grid above the stack, but only lifts large boxes from the stack at locations where the stack contains only boxes with a large footprint and multiple heights.

[0038] The load handling device lifts larger boxes from the stack into a chamber within the main body of the load handling device, thereby removing the boxes from the grid above the stack.

[0039] It should be understood that the above-described robotic load handling device is merely an embodiment of the present invention. Load handling devices capable of transporting boxes with any number of grid intervals in areas with a wide range of height possibilities are also conceivable.

[0040] The aforementioned picking system may refer to, for example, an order picking system designed for online retail, or a system such as a parcel handling and sorting system. It should be understood that the invention is applicable to any system in which items are stored in a stacked structure in containers and can be accessed by robotic handling equipment.

Claims

1. An article handling system, comprising: Two sets of substantially perpendicular tracks form a grid above a stack of containers; Containers at different heights within the stack; At least one robotic load handling device, operable on the grid, the robotic load handling device comprising a body mounted on wheels, the wheels comprising a first set of wheels configured to engage with at least two tracks of a first set of tracks and a second set of wheels configured to engage with at least two tracks of a second set of tracks, the first set of wheels being independently movable and actuated relative to the second set of wheels such that, during movement, only one set of wheels is engaged with the grid at any given time; The robotic load handling device is configured to lift and move the containers at different heights.

2. The article handling system of claim 1, wherein containers of different heights are stored in separate stacks.

3. The article handling system of claim 1, wherein the individual stacks comprise containers of different heights.

4. The article handling system of claim 1, wherein the robotic load handling device has a body height designed to accommodate the tallest of the containers of different heights.

5. The article handling system according to claim 1, wherein the robot load handling device has an area occupying one grid interval of the grid.

6. The article handling system according to claim 1, wherein the space occupied by the containers of different heights in the stack is all the area occupied by a single grid interval.

7. The article handling system of claim 1, wherein the container is located in the chamber of the body of the robotic load handling device when transported by the robotic load handling device.

8. The article handling system of claim 7, wherein the chamber is configured to receive a container with a height greater than its width.

9. A robotic load processing device, comprising: The main body has a cavity and is mounted on wheels; The first set of wheels is configured to engage with at least two tracks of the first set of rails; The second set of wheels is configured to engage with at least two tracks of a second set of tracks that are perpendicular to the first set of tracks; The first set of wheels can move and be driven independently relative to the second set of wheels, such that when in motion, only one set of wheels is engaged with the track at any given time; The load handling device is configured to lift containers from a stack of containers positioned below a grid formed by a first set of tracks and a second set of tracks, wherein the containers have different heights.

10. The robotic load handling apparatus of claim 9, wherein the body includes a chamber, and the load handling apparatus is configured to lift a container into the chamber.

11. The robotic load handling apparatus of claim 10, wherein the chamber has a height dimension sufficient to completely accommodate containers of different heights within the apparatus body.

12. The robotic load handling apparatus of claim 10, wherein the chamber is configured to receive a container with a height greater than its width.

13. The robot load handling device according to claim 9, having an area occupying one grid interval of the grid.

14. The robot load handling apparatus of claim 9, wherein the apparatus operates with reduced acceleration and speed.

15. An article handling system, comprising: Two sets of substantially perpendicular tracks form a grid above a stack of containers, the spacing of which defines the grid spacing. A first type of robot load processing device and a second type of robot load processing device, each of which is operable on the grid; The containers mentioned include containers of different heights. The first robotic load handling device is configured to lift and move a container to a first height, and the second robotic load handling device is configured to lift and move a container to a greater height.

16. The article handling system of claim 15, wherein the first type of robot load handling device and the second type of robot load handling device have an area occupying one grid interval.

17. An article handling system, comprising: Two sets of substantially perpendicular tracks form a grid above a stack of containers, the spacing of which defines the grid spacing. A first type of robot load processing device and a second type of robot load processing device, each of which is operable on the grid; The containers mentioned include containers with different cross-sectional areas. The first robotic load handling device is configured to lift and move a container with a first cross-sectional area, and The second robotic load handling device is configured to lift and move containers with a larger cross-sectional area.

18. The article handling system of claim 17, wherein the second robotic load handling device spans multiple grid intervals.

19. The article handling system of claim 17, wherein the container lifted by the second robotic load handling device has a cross-sectional area defined by an integer multiple of the grid spacing.

20. The article handling system of claim 17, wherein a portion of the grid is dedicated to stacking containing a more tolerant container.

21. An article handling system, comprising: Two sets of substantially perpendicular tracks form a grid above a stack of containers, the spacing of which defines the grid spacing. A first type of robot load processing device and a second type of robot load processing device, each of which is operable on the grid; The containers mentioned include containers of different heights and containers of different cross-sectional areas. The first robotic load handling device is configured to lift and move a container of a first height and a first cross-sectional area, and The second robotic load handling device is configured to lift and move containers with greater height and / or larger cross-sectional area.

22. The article handling system of claim 21, wherein the second robotic load handling device spans multiple grid intervals.

23. The article handling system of claim 21, wherein the containers with different cross-sectional areas have an area defined by an integer multiple of the grid spacing.

24. The article handling system of claim 21, wherein a portion of the grid is dedicated to stacking containers with greater height and larger cross-sectional area.

25. An article handling system, comprising: A first set of tracks and a second set of tracks substantially perpendicular to the first set of tracks form a grid above several stacked containers. The portion of the stacked containers includes boxes with a cross-sectional area larger than that of the containers in the remainder of the stack; The first set of tracks and the second set of tracks are configured to support several robotic load handling devices operating on the grid above the stacked containers; The first set of tracks and the second set of tracks define openings through which the stacked containers can be retrieved by the robotic load handling devices. The opening includes a portion with a larger cross-sectional area, through which the container with the larger cross-sectional area can be retrieved.

26. The article handling system of claim 25, wherein the grid spacing above the first portion of the stack has a grid cell size of 1×1, and the grid spacing above the second portion of the stack spans 2×2 grid cells.

27. The article handling system of claim 25, wherein a first set of wheels on at least one of the plurality of robotic load handling devices is configured to engage at least partially with a first set of tracks, and wherein a second set of wheels on at least one of the plurality of robotic load handling devices is configured to engage at least partially with a second set of tracks.

28. The article handling system of claim 25, wherein at least a portion of the first set of tracks or the second set of tracks is configured to support: a first robotic load handling device configured to retrieve a container of a first size and a second robotic load handling device configured to retrieve a container of a second size.

29. A robotic load handling device, the robotic load handling device comprising a body mounted on wheels and having a chamber sized to receive a container from an article handling system; The main body includes a first set of wheels configured to engage with at least two tracks of a first set of tracks and a second set of wheels configured to engage with at least two tracks of a second set of tracks perpendicular to the first set of tracks. Each set of wheels can extend, retract, and be driven independently relative to the other sets of wheels, such that when in motion, only one set of wheels is engaged with the track at any given time. The main body described herein has an area spanning multiple grid intervals, and The robotic load handling device is configured to lift and move a container having a cross-sectional area defined by an integer number of grid intervals.

30. The robotic load handling device of claim 29, wherein the first set of wheels is configured to engage with three adjacent tracks of the first set of tracks.

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