Storage system for compact three-dimensional storage of containers and method for operating such a storage system

Abstract

Storage system (1) for the compact three-dimensional storage of containers (10), wherein a two-dimensional, plane-based grid arrangement (2) of the storage system (1) is designed such that the containers (10) can be stored next to one another in each container plane (11) along a first horizontal coordinate axis (HK1) and next to one another along a second horizontal coordinate axis (HK2) with at least one container gap (L). According to the invention, the containers (10) can be both stored and retrieved by sliding along each first coordinate axis (HK1) and each second horizontal coordinate axis (HK2) by means of the at least one handling device (100) in the respective container plane (11) at the edge (4) of the respective container plane (11). The invention also comprises a method for operating such a storage system (1).

Description

The invention relates to a storage system for the compact three-dimensional storage of containers according to claim 1 and to a method for operating such a storage system according to claim 10.In the area of logistics, i.e. storing, removing items from storage and storing articles or goods in stores, the stores should allow as good a space utilization as possible with high dynamics or high throughput and low costs. Conventional bearings usually do not fulfil all of these requirements to the desired extent.DE 102 23 255 A1 discloses a storage system and a method in which containers are displaced along a coordinate axis in order to be able to remove a container perpendicular to the displacement direction from a row of containers lying behind these containers by means of an operating device. A container is discharged using the same storage and retrieval device, wherein containers are displaced along the coordinate axis in order to reach the row of containers lying behind and provided for the container to be discharged.From WO 2016 / 172793 A1, US 2015 / 0127143 A1, WO 2020 / 011355 A1, WO 2019 / 238697 A1 and WO 2019 / 238661 A1, robotic vehicles are known which move horizontally on top of the three-dimensional grid structure and implement a container exchange. However, the entire material flow runs over the upper side of the bearing.EP 3 362 379 A1 discloses a storage system in which a type of carrier vehicle can move (travel) on the ground as well as can climb on the rack on rails in order to move storage units and to put in or out of storage without lifts or conveyors etc. being necessary.In addition, it is likewise known to store in a level-based grid without gears ("puzzle-based storage" or "grid-flow storage"). Here, storage units may be sequentially moved to gain access to the units behind. It also offers the possibility of operating most compact stores in an automated manner (Gue, K. R. and B. S. Kim "Puzzle-Based Storage Systems", Naval Research Logistics 54(5), pp. 556-567.) Due to the arrangement of the loading units in a grid, a high-density storage or sorting is achieved, since no aisles are required to reach the loading units. If there is at least one void in the system, any desired load unit may be accessed. Other load units may have to be moved for this access.In contrast, the object of the present invention is to provide an alternative storage system for the compact three-dimensional storage of containers and a method for operating such a storage system, which has a high storage density and allows access to all containers located in the system with minimal expenditure of time and energy.This object is achieved by the bearing system having the features of claim 1 and the method having the features of claim 10. Advantageous embodiments are evident from the dependent claims and the description.According to the invention, a storage system for the compact three-dimensional storage of containers is provided, wherein a two-dimensional plane-based grid arrangement of the storage system is designed such that the containers can be stored in each case in a container plane next to one another along a first horizontal coordinate axis and next to one another along a second horizontal coordinate axis with at least one container gap, wherein the first horizontal coordinate axis and the second horizontal coordinate axis are perpendicular to one another, and the container planes are arranged one above the other, and the containers can be moved in the respective container plane individually or in container groups by means of at least one handling device of the storage system from the edge of the container plane in the first horizontal coordinate axis and in the second horizontal coordinate axis so as to be movable in an impact manner. The containers can be both introduced and removed via each first coordinate axis and each second horizontal coordinate axis by means of the at least one handling device in the respective container plane at the edge of the respective container plane by pushing.In other words, the containers are stored level by level in the manner of a puzzle-based storage or grid-flow storage, but only have to be displaced to the edge of the respective level in order to be adopted there at each outer grid point. The containers and container groups, for example rows, are displaced over the container gap until the desired container arrives at the edge of the plane and can be removed there. Thus, the shortest distance to the edge can be taken, since any location at the edge of the container plane is suitable for removal, since the handling device can move thereto. A container storage can take place over any container gap at the edge, which is either produced by displacement or is present in any case (e.g. directly after a storage process). The container groups are displaced by a container being directly contacted and displaced by the handling device. This container then passively pushes the further containers from the container group along the respective coordinate axis along which the group is to be displaced."On impact" means here that the containers touch one another during displacement.The plane-based grid arrangement has a multiplicity of vertically arranged supports and a container plane which is spanned perpendicular thereto along the first horizontal coordinate axis and second horizontal coordinate axis, wherein the containers can be mounted and moved on the container planes. The supporting components of the bearing are the supports which support the container planes on which the containers are again supported. The supports are preferably arranged externally as far as possible so that the displacement movement of the containers is not impaired.If it is necessary for static reasons to also arrange supports on the inside, these inner supports can be designed with guide elements in order to prevent the containers from getting caught when being displaced past a support.Thus, inner supports arranged within a container plane could be provided with spring grids arranged on the outer sides or outer corners for guiding the containers.The planar-based grid arrangement can be modular in design, so that it can be easily expanded in terms of capacity. This can be done in such a way that supports of a first container level also serve as supports of a second container level which is arranged at the same height level.In order to enable maintenance and segmentation of the working areas of the handling device(s) also in the interior of a container level, container-free empty lines can be provided, which can serve as access space for both maintenance personnel and for the handling device(s). The container-free blank line can accordingly extend along the first or the second coordinate axis. It thus brings about modularization of the container levels. Thus, the container groups displaceable by the handling device can also be kept manageable, since they can no longer be pushed together without disturbances from a certain length or size of the container plane.The clamped container planes can be provided with rollers, balls or slide coverings for friction reduction. This saves energy.In order to prevent the containers from being wedged or jammed, the clamped container planes can be designed with mechanical guide rails or magnets for positioning and guiding the containers.Thus, along the first or the second coordinate axis, guide rails can be arranged in the grid on the base, which guide rails engage in corresponding longitudinal or transverse recesses in the container base. The guide rails can be designed to be rigid or retractable and extendable. Furthermore, it is possible to arrange the guide rails completely or partially on the ceiling of the container levels, and not only in the floor.A contactless variant by means of magnets can also be used. Switchable electromagnets can be mounted on or in the bottom of the container plane and permanent magnets can be mounted in or on the underside of the containers. The arrangement of the magnets is variable. For example, one magnet can be arranged centrally or one magnet per corner or at the sides, etc. During the displacement process, the electromagnets are deactivated and the containers can be displaced freely.Once a translation operation is complete, one or more containers may not be fully centered along the corresponding coordinate axis. Then a short pulse of selected electromagnets may be sufficient to draw the containers on themselves and thus center them.A sliding force sensor on the handling unit can serve as a safety sensor, so that when a predetermined force threshold is exceeded, it can be assumed that a container blockage is present. Maintenance personnel or maintenance units (e.g. separate handling units) can then be notified. It is also conceivable to use other sensors (e.g. cameras) on the handling unit and / or on the grid arrangement.Appropriately positioned elastic wear parts such as rubber stoppers etc. would also be conceivable.Such measures also prevent undesired displacement of the containers by vibrations etc., since they fix the position of the containers at standstill.The containers are displaced by at least one handling device. For this purpose, this can be designed as guided on the edge of the upright outer supports and / or on the clamped container planes of the plane-based grid arrangement and / or as a robot vehicle that can be moved freely on the floor.It is possible to design the handling device as a pure unit climbing on the supports, which unit cooperates with further AGCs / AMRs on the ground in order to transfer containers. The configuration as an additional unit that can be moved on the floor would also be possible. For the transverse movement at the container level, on the one hand cross members of the supporting structure can be used or, on the other hand, separate running rails can be used. Both the supports and the transverse travel possibility can be provided with power charging mechanisms in order to supply the handling device and / or to enable charging of power storage devices (powercap, rechargeable battery, etc.). The current charging mechanism can function inductively or, for example, via loads (contact line).In other words, the handling device must be able to move on the outside of the grid arrangement and to push containers therein or on a container plane both to the left and to the right and also to the front, that is to say in both coordinate axis directions.The handling device can thus be configured to shift containers into a first coordinate axis and a second horizontal coordinate axis of the respective container plane.The handling device could also be equipped with a multi-stage displacement mechanism, e.g. in the form of a plurality of telescopic stages, in order to displace containers further, e.g. to displace two or even three grid positions (storage locations).Furthermore, the handling device can be designed such that it can receive and transport individual containers, e.g. pull them up on them, for example during the unloading of a target container.The handling device is accordingly configured to receive a container.It is also conceivable to use a plurality of handling devices simultaneously. The simultaneous use can take place both at the same level and at different levels. In this case, a plurality of handling devices can cooperate or be controlled cooperatively. Thus, for example, two handling devices can operate on different sides of a container group. One handler and the other concurrently receives the thus shifted target container. This results in a more rapid displacement or provision of the target containers.The energy supply of the handling device can be effected by a battery or by charging contacts / inductive charging with the aid of the shelf rails.The term "compact" is understood within the scope of the invention to mean that no handling device is arranged between the containers, as is the case, for example, in storage systems with storage racks arranged parallel to one another and in storage and retrieval devices that can be moved in a rack aisle arranged therebetween. Thus, no free space which it requires for direct removal of goods is kept available, but rather is produced only when necessary. In this case, only the smallest possible free space which is produced for removing the container and / or article is produced, which preferably corresponds to a single container width or container length.The three-dimensional grid arrangement is preferably cuboidal and has, at least in each container plane, a container-free storage location into which the containers can be moved or displaced.The at least one first horizontal coordinate axis along which the containers are movable or displaceable is the X axis. The at least one second horizontal coordinate axis is the Y axis arranged perpendicular to the X axis.The storage system according to the invention has a high storage density and permits direct access to the goods with minimal expenditure of time and energy.The invention further relates to a method for operating a storage system according to one of the preceding claims, wherein containers stored next to one another in the two-dimensional plane-based grid arrangement of the storage system are displaced individually or in container groups along the first horizontal coordinate axis and along a second horizontal coordinate axis, preferably exactly by a container width or container length, by means of the first handling device of the storage system over the at least one container gap until a desired container is positioned at the edge region of the container plane and subsequently the desired container is removed by means of the first handling device at the edge of the container plane either in the first horizontal coordinate axis or in the second horizontal coordinate axis.In other words, the containers and container groups, e.g. rows, are displaced over the container gap until the desired container arrives at the edge of the plane and can be removed there. Thus, the shortest distance to the edge can be taken, since any location at the edge of the container plane is suitable for removal, since the handling device can move thereto.The storage system according to the invention has a controller which is designed and set up to carry out the method according to the invention.Further details of the invention will become apparent from the following description of exemplary embodiments with reference to the drawing, in which FIG. 1 shows a schematic perspective view of a storage system for the compact three-dimensional storage of containers, FIG. 2 shows a schematic plan view of a section of a three-dimensional grid structure of the bearing system from FIG. 1, FIG. 3 shows a schematic plan view of an exemplary three-dimensional grid structure during the displacement of a target container, FIG. 4 shows a schematic plan view of a detail of a three-dimensional grid structure of the storage system from FIG. 1 during the removal of a container; and FIG. 5 shows a schematic perspective view of a handling device on the storage system from FIG. 1 ; FIG. 6 shows a schematic top view of a variant of a bearing system; FIG. 7 is a schematic side view of a container with a guide interacting with the bottom of the container; FIG. 8 shows a schematic top view of a section of a container plane with inner supports, and FIG. 9 shows a schematic top view of a container plane with a centering mechanism show.In the figures, a storage system, denoted as a whole by 1, for the compact three-dimensional storage of containers 10 is illustrated.It is formed by a two-dimensional plane-based grid arrangement 2 such that the containers 10 can be stored next to one another along a first horizontal coordinate axis HK 1 and next to one another along a second horizontal coordinate axis HK 2 with at least one container gap L in each case in a container plane 11.Here, the first horizontal coordinate axis HK 1 (X direction) and the second horizontal coordinate axis HK 2 (Y direction) are perpendicular to each other, and the container planes 11 are vertically arranged one above the other in the Z direction.In other words, the containers 10 stand in rows 3 a, 3 bin the respective container plane 11 which are at right angles to one another, and these container planes 11 are arranged vertically one above the other.The plane-based grid arrangement 2 comprises a plurality of supports 6 arranged upright and on the outside. The container planes 11 spanned perpendicular thereto along the first horizontal coordinate axis HK 1 and second horizontal coordinate axis HK 2 have running rails 7 on the edge 4.The clamped container planes 11 are provided with slide coverings for friction reduction.This results in a cube-shaped structure, wherein the respective container planes 11 are initially independent of one another. The construction is compact since no conventional rows and gears are provided for accesses.The access to containers or their displacement takes place only via the edge 4 of the respective container plane 11 by means of handling devices 100 designed as robot vehicles which can be moved there.These robot vehicles 100 can climb along the outside of the supports 6 and traverse along the running rails 7 at the container planes 11.The robot vehicles 100 each have a container displacement mechanism 101 with which the containers 10 can be moved in the respective container plane 11 individually or in container groups 12, e.g. rows, from the edge 4 of the container plane 11 in an impact-displaceable manner in the first horizontal coordinate axis HK 1 and in the second horizontal coordinate axis HK 2 (see FIGS. 2 and 3 below).For this purpose, the container sliding mechanism 101 comprises a linearly extendable plunger 102 and an adjoining gripping head 103 which is configured to stabilize the adjacent container 10 with side cheeks 103 a, bin a partially enclosing manner.By means of the container displacement mechanism 101, an individual container 10 or a container group 12 can thus be displaced by at least one container length or container width. If the containers 10 are square in section as in the present case, a checkerboard-like arrangement and thus also linear displacement in the direction of the second coordinate axis HK 2 or in the Y direction results by extending the punch 102 (see FIG. 2A ).For the transverse displacement in the direction of the first coordinate axis HK 1 or X direction, the robot vehicle 100 engages around the respective container 10 located at the edge with the side cheeks 103 a, band itself travels along the running rail 7 in the desired direction and by the required extent (cf. FIG. 2B ).In order to move a desired target container 10* from a position within the container plane 11 to the edge 4 into the direct access region of a robot vehicle 100, the containers 10 and container rows 12 can be shifted alternately in the directions of the first coordinate axis HK 1 or X direction and the second coordinate axis HK 2 or Y direction until the desired target container 10* reaches the edge 4.This is illustrated by way of example in FIG. 3 on the basis of displacement movements i) - vii). There, first of all, during the movement i, two containers 10 are pushed inward into the gap L as a row 12.1. Subsequently, in the movement ii, an individual container is pushed into the newly created gap L 2. Thereafter, the entire row 12.2 of containers is pushed into the new gap L3 in movement iii. Thus, the gap L 4 now created can serve to accommodate the row of containers 12.3 from movement iv. Then, in the movement v, the outer container row 12.4 is displaced into the gap L5, so that a gap L6 is produced at the corner. The row of containers 12.5 can be pushed into the latter in the movement vi, as a result of which a gap L7 is produced at the edge in front of the target container 10*, in which gap the latter is pushed in by a last movement viiof the row 12.6 and is now in access (cf. FIG. 4 at the bottom).Furthermore, the robot vehicles 100 have a receptacle 104 (see FIG. 4 ) into which containers 10 can be received for transport. For this purpose, the container sliding mechanism 101 can be designed as an additional pulling mechanism. Alternatively, a further robot vehicle 100 can push the corresponding container row 12 from the remote side in such a way that the desired container 10 is pushed onto the waiting robot vehicle 100 into the receptacle 102.The robot vehicle 100 can then leave the respective container level 11 and climb down to the hall floor 5 (or, if applicable, an intermediate level), where it can transfer the container 10 to a waiting AGC or AMR 9 that has been ordered there by a superordinate central controller 200.As shown in FIG. 5, the robot vehicle 100 can engage with a drive 105 in toothed racks 16 of the supports 6 in a form-fitting manner in order to move upwards and downwards thereon. Analogously, a drive 106 can interact with the running rails 7 for the in-plane transverse method.FIG. 6 shows a variant of the storage system 1, in which the plane-based grid arrangement 2 is of modular design and a container-free empty line 13 is arranged between two modules 2A, 2B or their vertically arranged supports 6 in the direction of the first or the second coordinate axis HK 1, HK 2. This empty line 13 allows, on the one hand, access for a robot vehicle 100, so that the size of container rows 12 to be handled remains manageable, and, on the other hand, access for maintenance which may be necessary.The bearing system 1 according to the invention can be equipped with mechanical guide rails or magnets in the clamped container planes 11 for positioning and guiding the containers 10.FIG. 7 shows a variant with mechanical guide rails 14.Thus, along the first and the second coordinate axis HK 1, HK 2, guide rails 14 a, bmay be arranged in a grid on the bottom of the container plane 11, which guide rails engage in corresponding longitudinal or transverse recesses 10 a, bin the container bottom 10 c.The guide rails 14 are designed to be retractable and extendable in recesses 11 a, bin the ground. Thus, the containers 10 are guided during the pushing and cannot slip and also cannot be displaced by vibrations during standstill.FIG. 8 illustrates a variant in which, for example for static reasons, the container planes 11 have, in addition to the supports 6, also inner supports 6A on the outside in order to handle the load. In order that the containers 10 during the displacement process do not remain hanging on these inner supports and may become wedged, the inner supports 6A are provided on all four sides with spring grids 15 for guiding the containers 10. These prevent the containers 10 from sticking to the inner supports 6A. The thus spring-mounted grids 15 can, upon contact with the containers 10, first yield due to the pressure against the spring during displacement (cf. arrow) and then spring back in order to ensure positioning of the containers 10. It is understood that the distances shown are depicted enlarged for the purpose of illustration.As shown in FIG. 9, a contactless variant can also be used by means of magnets 17 and 18. Switchable electromagnets 18 are mounted on or in the bottom of the container plane 11 and permanent magnets 17 are mounted centrally in or on the underside of the containers 10. During the displacement process, the electromagnets 18 are deactivated and the containers 10 can be displaced freely.As soon as a displacement process is completed, it could be that a container 10 is not completely centered along the corresponding coordinate axis HK 1, HK 2. Then, a short impulse of an electromagnet 18 to be activated (or optionally all or certain areas) may be sufficient to draw the container 18 on itself and thus center it. The controller 200 is configured accordingly for this purpose. It is also possible to carry out a pulse at the beginning of a sliding operation in order to ensure that the containers are aligned before the sliding.A sliding force sensor 19 on the handling unit 100 serves as a safety sensor, so that when a predetermined force threshold is exceeded, it can be assumed that a container blockage is present. Maintenance personnel or maintenance units (e.g. separate handling units) can then be notified if an alignment by means of the magnets 17, 18 is not successful.References included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedDE 102 23 255 A1

[0003] WO 2016 / 172793 A1

[0004] US 2015 / 0127143 A1

[0004] WO 2020 / 011355 A1

[0004] WO 2019 / 238697 A1

[0004] WO 2019 / 238661 A1

[0004] EP 3 362 379 A1

[0005] Cited Non-Patent LiteratureGue, K.R. and B.S. Kim, "Puzzle-Based Storage Systems", Naval Research Logistics54(5), pp. 556-567

[0006]

Claims

Storage system (1) for the compact three-dimensional storage of containers (10), wherein a two-dimensional plane-based grid arrangement (2) of the storage system (1) is designed such that the containers (10) can be stored in each case in a container plane (11) next to one another along a first horizontal coordinate axis (HK1) and next to one another along a second horizontal coordinate axis (HK2) with at least one container gap (L), wherein the first horizontal coordinate axis (HK1) and the second horizontal coordinate axis (HK2) are perpendicular to one another, and the container planes (11) are arranged one above the other, and the containers (10) can be moved in the respective container plane (11) individually or in container groups (12) by means of at least one handling device (100) of the storage system (1) from the edge of the container plane (11) in an impact-displaceable manner in the first horizontal coordinate axis (HK1) and in the second horizontal coordinate axis (HK2), characterized in that the containers (10) can be stored and removed by sliding in the respective container plane (11) at the edge of the respective container plane (11) via each first coordinate axis (HK1) and each second horizontal coordinate axis (HK2) by means of the at least one handling device (100).Storage system (1) according to claim 1, characterised in that the plane-based grid arrangement (2) has a plurality of vertically arranged supports (6) and container planes (11) spanned perpendicular thereto along the first horizontal coordinate axis (HK1) and second horizontal coordinate axis (HK2), wherein the containers (10) can be stored and moved on the container planes (11).Storage system (1) according to claim 2, characterised in that inner supports (6) arranged within a container plane (11) are provided with spring grids (15) arranged on the outer sides (6*A) or outer corners for guiding the containers (10).Storage system (1) according to one of claims 2 or 3, characterised in that the plane-based grid arrangement (2) is of modular design and a container-free empty line is arranged between two modules or their vertically arranged supports (6) in the direction of the first or the second coordinate axis (HK1, HK2).Bearing system (1) according to one of Claims 2 to 4, characterized in that the clamped container planes (11) are provided with rollers, balls or slide coverings for friction reduction.Storage system (1) according to one of Claims 2 to 5, characterized in that the clamped container planes (11) have mechanical guide rails (14A, B) or magnets (11C) for positioning and guiding the containers (10).Storage system (1) according to one of Claims 1 to 6, characterized in that the handling device (100) is designed as guided on the edge of the upright outer supports (6A) and on the clamped container planes (11) of the plane-based grid arrangement (2) and / or as a robot vehicle which can be moved freely on the ground.Storage system (1) according to Claim 7, characterized in that the handling device (100) is configured to shift containers (10) into a first horizontal coordinate axis (HK1) and a second horizontal coordinate axis (HK2) of the respective container plane (11).Storage system (1) according to claim 7 or 8, characterised in that the handling device (100) is configured to receive a container (10).Method for operating a storage system (1) according to one of the preceding claims, wherein containers (10) stored next to one another in the two-dimensional plane-based grid arrangement (2) of the storage system (1) are displaced individually or in container groups (12) along the first horizontal coordinate axis (HK1) and along a second horizontal coordinate axis (HK2), preferably exactly by a container width or container length, by means of the first handling device (100) of the storage system (1) over the at least one container gap (L) until a desired container (10) is positioned at the edge region of the container plane (11) and subsequently, by means of the first handling device (100), the desired container (10) is discharged at the edge of the container plane (11) either in the first horizontal coordinate axis (HK1) or in the second horizontal coordinate axis (HK2).

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