Method for the sequenced storage and retrieval of packages into or from a rack storage system and corresponding rack storage system

Abstract

The invention relates to a method for the sequenced storage and retrieval of packages into or from a rack storage system (1) and a corresponding rack storage system, wherein - the packages (P) are stored in several storage rack aisles (2) and storage rack levels (3) in shelf compartments (4), - the packages (P) are stored in or out of the shelf compartment (4) via at least one storage and retrieval machine (5) per storage aisle (2), - for each storage aisle (2) a package storage lift (6) is used upstream of the storage and retrieval machine (5), which conveys the packages (P) to the respective shelf level (3) and from which the storage and retrieval machine (5) takes over the packages directly or indirectly (P), - for each storage aisle (2) a package removal lift (7) downstream of the storage and retrieval machine (5) is used, which takes the packages (P) directly or indirectly from the storage and retrieval machine (5) and transports them away, - the package storage lift (6) is supplied by a storage conveyor line (8) and the package removal lift (7) supplies a removal conveyor line (9). To increase throughput, the invention provides that a second package input lift (10) or second package output lift (11) is arranged between the package input lift (6) and the input conveyor (8) and / or the package output lift (7) and the output conveyor (9), which exchanges packages with the first package input lift (6) or first package output lift (7), for which purpose the first package input lift (6) is supplied by the second package input lift (10) and the first package output lift (7) supplies the second package output lift (11).

Description

[0001] The invention relates to a method for the sequenced storage and retrieval of packages into or from a rack storage system according to claim 1 and a corresponding rack storage system according to claim 11.

[0002] Storage racking systems with shuttles as storage and retrieval machines have lifts that exchange transport units or packages with the shuttles to supply the racking system with packages or retrieve them. Retrieval is usually targeted to supply downstream picking stations with packages in a specific order and sequence to fulfill or process orders. Various configurations of such systems are known from EP 2 794 430 A1.

[0003] From EP 1 964 792 B1, a storage rack of the type is known in which transport units are retrieved by targeted control in a desired sequence and transferred to corresponding reserved places of a collection route.

[0004] From DE 10 2011 014 394 A1, a circular roaming of rack storage systems with shuttles is known, which are used simultaneously in one and the same rack aisle at the same height.

[0005] From DE 10 2023 101 283 B3 a goods storage and order picking system with a load lifting device is known, which is arranged as a storage lift over the entire height of the storage rack.

[0006] In modern e-commerce applications with small order sizes, faster processing with high requirements for order sequencing is desired, as the products in such small orders, with e.g. one to four products per order, should be delivered directly one after the other to picking stations.

[0007] Sequencing may also be desirable during storage, for example, if packages need to be distributed to specific levels within a warehouse. This is necessary if, for instance, packages with the same item number are to be evenly distributed throughout the warehouse to ensure a wide selection for later retrieval.

[0008] However, it turns out that with such arrangements as those known from EP 1 964 792 B1, the required throughput cannot be achieved while maintaining the necessary sequence. In other words, sequencing consumes enormous amounts of power.

[0009] In contrast, the object of the present invention is to provide a method for the sequenced storage and retrieval of packages into or from a rack storage system and a corresponding rack storage system in which the throughput is higher despite adherence to a desired sequence.

[0010] This problem is solved by the method described in claim 1 and the storage rack system according to claim 11. Advantageous embodiments are described in the dependent claims and the description.

[0011] According to the invention, it has been recognized that if a second package input lift or a second package output lift is arranged between the package input lift and the input conveyor and / or the package output lift and the output conveyor, and this second package output lift exchanges packages with the first package input lift or first package output lift, respectively, with the first package input lift being supplied by the second package input lift and the first package output lift supplying the second package output lift, it becomes possible to increase the throughput despite sequenced provisioning.

[0012] Investigations by the applicant show that almost 50% throughput improvement is achievable, even though an additional lift only increases costs by about 25% compared to a simple lift.

[0013] In other words, two lifts connected in series are provided for both retrieval and storage, and these lifts are controlled cooperatively as a pair. This allows the first retrieval lift, located near the storage rack, to transfer packages to the second retrieval lift to relieve its load, enabling it to be refilled more quickly from the storage rack. Meanwhile, the second retrieval lift can transfer its load to the outbound conveyor. The reverse process applies to the storage operation.

[0014] The package storage lift(s) are used to supply (replenish) the rack storage system with packages, replenishing packages that are running low and, if necessary, optimizing their positioning within the rack storage system. The package removal lift(s) are used to remove packages from the rack storage system, retrieving the requested packages for further processing within the system, e.g., for order-oriented picking.

[0015] If the first package storage lift is pre-positioned on the target level to take over packages from the second package storage lift, the transfer can take place without delay, which optimizes storage performance.

[0016] If the second package retrieval lift is pre-positioned at the source level to take over packages from the first package retrieval lift, the transfer can take place without delay, which optimizes retrieval performance.

[0017] The exchange of packages between the inbound and outbound machines and the first package inbound lift or first package outbound lift can be carried out indirectly via buffer conveyors, which are then arranged in the storage rack levels adjacent to the package lifts. Preferably, the buffer conveyors are integrated into the racking in such a way that they can be accessed by the inbound and outbound machines as if they were storage compartments. This allows the inbound and outbound machines to be decoupled from the lifts. The buffer conveyors can then supply and empty the lifts.

[0018] Each lift can be equipped with a vertically movable lifting platform, each of which is fitted with a conveyor that has space for one or two packages. The conveyor can be a roller conveyor or a belt conveyor. The conveyor can also be equipped with two or more zones that can be controlled and operated individually or together. Preferably, the second lift always has two positions for packages on the lifting platform. Then, during the transfer to or from the first lift, two packages are transferred or received simultaneously.

[0019] Furthermore, it is advantageous if each lift has a separately driven conveyor for each station. In particular, it is beneficial if each lift has two stations, each equipped with a separately driven conveyor.

[0020] To further increase throughput, the vertically movable lifting platforms can be double-decked. The two lifting platforms can move together or separately. Accordingly, more than one inbound and / or outbound conveyor line can be provided. These can, for example, be arranged vertically one above the other at a distance corresponding to the spacing of the rack levels or the spacing of the lifting platforms.

[0021] Preferably, the lifts are arranged at one of the ends of the storage rack aisles and connected there to the inbound and / or outbound conveyor system. However, it is also conceivable that the lifts are arranged within the racking system, allowing the inbound and outbound machines to pass them in the racking aisle. In this case, the inbound and / or outbound conveyor system could be located on a level above and / or below the storage racking system. Arrangement on an intermediate level between the upper and lower storage racking areas would also be possible. Separate (different) arrangements of the package inbound and package outbound lifts are also an option.

[0022] If the lifts are arranged within the racking system so that the storage and retrieval machines can pass them in the racking aisle, then one lift, preferably the second package storage lift or the second package retrieval lift, can not only be connected to the storage or retrieval conveyor above and / or below, but can also directly deliver packages to or receive packages from the adjacent racking system. It is particularly efficient if, during delivery, packages are simultaneously received from the first package retrieval lift.

[0023] It is preferred if the package storage lifts and the package retrieval lifts are each aligned with one side of a storage rack aisle.

[0024] To simplify maintenance, control and installation, it may be intended that the lifts are identical.

[0025] To achieve high throughput of the entire system, at least one storage and retrieval machine can be provided per storage rack level. This eliminates the need to change rack levels. Preferably, the storage and retrieval machine is a single-level storage and retrieval system of the shuttle type.

[0026] The invention also relates to a storage rack system for the sequenced storage and retrieval of packages into or from an associated rack storage system with a control system according to claim 11. The rack storage system comprises several rack aisles and rack levels with rack compartments for storing packages (P) and at least one storage and retrieval machine per rack aisle for the controlled storage and retrieval of the packages into or from the rack compartments, as well as one controlled package input lift and one controlled package output lift per rack aisle, each configured to convey or remove packages to the respective rack level and to transfer or receive packages directly or indirectly to or from the storage and retrieval machine.The storage racking system comprises an inbound conveyor and a retrieval conveyor, with the package inbound lift connected to the inbound conveyor and the package outbound lift connected to the outbound conveyor. The storage racking system also includes a second controlled package inbound lift and / or a second controlled package outbound lift, with the second controlled package inbound lift or the second controlled package outbound lift being arranged between the package inbound lift and the inbound conveyor and / or the package outbound lift and the outbound conveyor. Each of these is configured to exchange packages with the first package inbound lift or the first package outbound lift, respectively. For this purpose, the first package inbound lift is supplied by the second package inbound lift, and the first package outbound lift supplies the second package outbound lift in a controlled manner.

[0027] In other words, the respective package storage lifts and / or package retrieval lifts are arranged adjacent to each other and exchange packages in order to increase the throughput of the corresponding conveying direction, storage or retrieval, by decoupling the transfer from the rack or storage or retrieval conveyor line.

[0028] Packages include parcels, containers, trays, cartons, etc. It is understood that the term "packages" is not to be interpreted restrictively, but rather that other modes of transport (e.g., trays, pallets, etc.) can be used with equal success within the scope of the invention. The term "transport units" specifically includes trays, containers, cartons, parcels, packaging units—i.e., grouped individual items, etc.—and individual items.

[0029] Suitable storage and retrieval machines include stacker cranes that travel in the aisle, supplying and removing items from the racks on both sides of the aisle, and delivering and receiving packages to and from the lifts, or exchanging them with buffer conveyors. Preferably, these storage and retrieval machines are single-level stacker cranes or so-called shuttle vehicles that travel on rails along the aisle at different rack levels, supplying and removing items from the racks on both sides of the aisle at a single level. These shuttle vehicles then operate the lifts near the racks either directly or indirectly via the buffer conveyors.

[0030] The packages are stored in several aisles and levels of shelving, in individual storage compartments. These storage locations are arranged either single-deep or multi-deep in a row. The loading and unloading machines are designed to reach the appropriate depth into the shelving on both sides of the aisle to handle the packages.

[0031] The storage shelves are arranged alternately (except at the edge of the warehouse) back-to-back without gaps or spaced apart by a shelf aisle.

[0032] Between two back-to-back storage racks, packages can be directly exchanged from one rack aisle to an adjacent one via cross conveyors within the racks. This eliminates the need for distribution and / or complex sorting in the pre-storage zone, as the packages are retrieved already sorted, even if they were not initially located in the same rack aisle. This is because they are temporarily stored in the retrieving aisle, even if they were initially stored elsewhere. Thus, without distribution or sorting outside the aisles, a direct transfer of packages can be achieved without intersecting conveyors, with reduced and simplified technical effort, a smaller footprint, and high reliability. The packages can therefore be easily retrieved from their respective aisles in the required sequence.According to the invention, the inbound and outbound machine handles the movement of the packages in the transverse conveyor positions; that is, there is no other active drive technology in the rack, but rather the inbound and outbound device itself is the only active mechanism for transverse transfer. In particular, the inbound and outbound machine places the packages from the source aisle directly into the transverse conveyor positions of the destination aisle (by means of multi-deep storage), so that the inbound and outbound device of the adjacent destination aisle has easy access to them.

[0033] In particular, it is a fully automated warehouse.

[0034] In other words, shelf storage spaces of adjoining shelves are used to pass transport units from one side of the shelf to the next, so that the packages can be transferred from one shelf to the next as in a pass-through.

[0035] This makes cross-conveying or sorting possible within the shelves themselves, and thus eliminates the need for "cross-conveying" in the pre-zone.

[0036] Ideally, cross conveyor stations should be provided on every level of the storage racks or on selected levels.

[0037] Particularly good path-time optimization is achieved when the cross conveyor stations are located centrally or along the length of the racking, closer to the retrieval or storage lift. It is also possible to provide several cross conveyor stations on the same level, possibly at different positions.

[0038] The cross conveyor stations can also serve as temporary storage, meaning the packages remain there until they are actually needed or retrieved. This is particularly useful if the cross conveyor stations are part of the package's final destination aisle.

[0039] The exchange can be active or passive with respect to the storage and retrieval machine; that is, the transverse conveyor station can simply be a passive storage area where the storage and retrieval device of one aisle places transport units (essentially stores them) and from which the storage and retrieval machine of the adjacent aisle receives transport units (essentially retrieves them). This process can occur in only one direction or in both directions for each rack storage location or transverse conveyor station.

[0040] The cross-conveyor stations can therefore be designed for either bidirectional or unidirectional and / or active or passive exchange.

[0041] The storage and retrieval machines can also store packages in the cross conveyor stations at double depth or multiple depths for exchange. The storage and retrieval machines of one aisle can therefore store packages in the cross conveyor stations so deeply that they are already considered part of the adjacent rack and are "normally" accessible by the corresponding storage and retrieval machine.

[0042] For this purpose, the load-handling devices of the storage and retrieval machines, e.g. telescopic rail arms, can have an extended reach.

[0043] Preferably, the inbound conveyor lines are connected to at least one replenishment area from which goods or packages are delivered for restocking. This can be a high-bay pallet warehouse with an integrated depalletizing system and / or a receiving area.

[0044] Preferably, the outbound conveyor lines are connected to at least one picking area where the packages are picked manually and / or robot-assisted at goods-to-person stations in an order-oriented manner and completed orders are conveyed to a goods issue area, and / or to a goods issue area.

[0045] The transfer from one lift to another, or from a buffer conveyor to a lift or vice versa, as well as the transfer to a storage conveyor or the takeover from a receiving conveyor, can be executed by initiating (starting) the transfer early enough to take place from the higher source lift or conveyor to the lower destination lift or conveyor and to be completed when they are approximately horizontally aligned. The principle is to make the lift ready for the transfer as early as possible. A load transfer can only be initiated once the lifting platform has reached a certain height and has leveled off at the transfer plane, i.e., is aligned with the adjacent conveyor or the other lifting platform, to prevent a load from colliding with either the lifting platform or the buffer conveyor.Normally, leveling is performed with a tolerance of no more than 3 mm to prevent collisions. However, to achieve this, the lift must undergo a positioning process consisting of a certain amount of slow creeping towards the transfer level and a settling period during which the lift carriage (lifting platform) springs, oscillates, or vibrates. To minimize or eliminate this slow and time-consuming creeping and settling process, the lifting platform is moved beyond the transfer level. In other words, the transfer is controlled to occur before the lifting platforms, conveyors, etc., are at the same height, by transferring the load from the higher level to the lower level. There is no need to wait for the leveling process to complete.

[0046] Further details of the invention will become apparent from the following description of exemplary embodiments with reference to the drawing, in which Fig. 1. A schematic perspective view of a shelf warehouse; Fig. 2 a top view of the rack storage Fig. 1 in the area of ​​the lifts; Fig. 3 a side view of the shelf storage Fig. 2; Fig. 4 schematic side views of different phases of the package lift movements of the rack storage system Fig. 1. During outsourcing; and Fig. 5 A schematic side view of a variant of a rack storage system with integrated lifts show.

[0047] In the Fig. Figures 1 to 3 show a storage rack system 1000 for the sequenced storage and retrieval of packages P into or from an associated rack storage 1 with a control system 100.

[0048] The rack storage facility 1 comprises several rack aisles 2 with spaced-apart racks 15 and rack levels 3 with shelf compartments 4 for storing packages P. It is understood that only a section is shown here.

[0049] For storage and retrieval, shuttles 5 operate as storage and retrieval machines 5 in each storage rack level 3 and storage rack aisle 2 for controlled storage and retrieval of the packages P into or out of the rack compartments 4.

[0050] Each storage aisle 2 has a controlled first package storage lift 6 and a controlled first package removal lift 7, each designed to convey or remove packages P to the respective storage shelf level 3.

[0051] The packages P are indirectly transferred to and from the shuttles 5. For this purpose, buffer conveyors 12 are arranged in the storage rack 15 on each storage rack level 3 adjacent to the first package lifts 6, 7. These conveyors facilitate the exchange of packages P between shuttle 5 and lifts 6, 7.

[0052] The storage racking system 1000 has an inbound conveyor line 8 and an outbound conveyor line 9 for each storage rack aisle 2, and the first package inbound lift 6 is connected to the inbound conveyor line 8 and the first package outbound lift 7 is connected to the outbound conveyor line 9.

[0053] The storage racking system 1000 additionally includes a second controlled package infeed lift 10 and a second controlled package outfeed lift 11 per storage rack aisle 2.

[0054] The second controlled package storage lift 10 is arranged between the first package storage lift 6 and the storage conveyor 8, and the second controlled package removal lift 11 is arranged between the first package removal lift 7 and the removal conveyor 9.

[0055] The second controlled package storage lifts 10 and the second controlled package ejection lifts 11 are each designed to exchange packages P in a controlled manner with the first package storage lift 6 and first package ejection lift 7 respectively, whereby the first package storage lift 6 is supplied by the second package storage lift 10 and the first package ejection lift 7 supplies the second package ejection lift 11 in a controlled manner.

[0056] Therefore, two pairs of cooperating lifts are provided per storage rack aisle.

[0057] All lifts 6, 7, 10, 11 are identically constructed and arranged at one of the end sides of the storage rack aisles 2, and the package storage lifts 6, 10 and the package removal lifts 7, 9 are each aligned with one side of a storage rack aisle 2.

[0058] Each lift 6, 7, 10, 11 runs vertically over the entire height of the storage rack 1 or the storage racks 15 and is equipped with a vertically movable lifting platform 13, each equipped with a conveyor 13B which has space for two packages P, each equipped with a separately driven conveyor 13B1, 13B2.

[0059] In the Fig. Figure 4 schematically illustrates how the cooperating package retrieval lifts 7 and 11 achieve an increase in throughput. The opposite applies to the storage variant.

[0060] First, a package P1 to be retrieved is transferred from the respective buffer conveyor 12 to the lifting platform 13 of the first rack-adjacent package retrieval lift 7, whereby the package P1 is picked up on the first conveyor 13B1 (I).

[0061] The lifting platform 13 of the package removal lift 7 is then positioned at the storage rack level 3 of the next package P2 to be removed.

[0062] When the next package to be retrieved, P2, is transferred to the first conveyor 13B1, this conveyor simultaneously conveys the first package to be retrieved, P1, to conveyor 13B2 (II). Thus, the lifting platform 13 of the package retrieval lift 7 is now doubly occupied.

[0063] However, this now does not travel to the outbound conveyor 9, but to the next storage rack level 3 of the next package to be outbound, P3. The lifting platform 13 of the second package outbound lift 11 has already been pre-positioned there (III).

[0064] Now, the package P3 to be removed is simultaneously picked up on the first conveyor 13B1 of the lifting platform 13 of the package removal lift 7 and both previous packages P2 and P1 are transferred to the lifting platform 13 of the second package removal lift 11 (IV).

[0065] The second package unloading lift 11 can now travel to the unloading conveyor line 9 to deliver packages P2 and P1, while the package unloading lift 7 can travel to the next target level for the next package to be unloaded, P4. The process then repeats.

[0066] In Fig. Figure 5 shows the operation of a variant 1000* of the storage rack system 1000, in which the lifts 6, 7, 10, 11 are integrated into the storage rack 15 in such a way that the shuttles 5 can pass by them, and the storage conveyor lines 8 and the retrieval conveyor lines 9 are arranged in a level below the storage rack 15.

[0067] Thus, the second package lifts 10, 11 are equipped with a correspondingly extended vertical travel length in order to connect to the storage conveyor lines 8 and the outbound conveyor lines 9.

[0068] With such an arrangement, the transfer of packages P2, P1 from the first package removal lift 7 to the second package removal lift 11 can be accompanied by a transfer from the latter to the adjacent buffer conveyor 12 in the storage rack 15.

[0069] This variant thus allows for simultaneous storage and retrieval. The respective package storage lifts and package retrieval lifts are arranged adjacent to each other and exchange packages to increase throughput in the corresponding conveying direction, storage or retrieval, by decoupling the transfer from the rack or storage / retrieval conveyor line. Reference symbol list 1000 storage racking system 1000* storage racking system P package P1 package P2 package P3 package P4 package 100 Control 1 shelf storage 2 storage rack aisles 3 storage rack levels 4 shelf compartments 5 Shuttle 6 first package storage lift 7 first package outload lift 8 storage conveyor lines 9 outfeed conveyor lines 10 second package storage lift 11 second package outload lift 12 buffer conveyors 13 Lifting platform 13B Conveyor 13B1 Supporter 13B2 Supporter 15 storage rack

Claims

[1] Method for the sequenced storage and retrieval of packages into or from a rack storage system (1), wherein - the packages (P) are stored in several storage rack aisles (2) and storage rack levels (3) in shelf compartments (4), - the packages (P) are stored in or out of the shelf compartment (4) via at least one storage and retrieval machine (5) per storage aisle (2), - for each storage aisle (2) a package storage lift (6) is used upstream of the storage and retrieval machine (5), which conveys the packages (P) to the respective shelf level (3) and from which the storage and retrieval machine (5) takes over the packages directly or indirectly (P), - for each storage aisle (2) a package removal lift (7) downstream of the storage and retrieval machine (5) is used, which takes the packages (P) directly or indirectly from the storage and retrieval machine (5) and transports them away, - the package infeed lift (6) is supplied by an infeed conveyor (8) and the package outfeed lift (7) supplies an outfeed conveyor (9), characterized by , that a second package storage lift (10) or second package removal lift (11) is arranged between the package storage lift (6) and the storage conveyor (8) and / or the package removal lift (7) and the removal conveyor (9), which exchanges packages with the first package storage lift (6) or first package removal lift (7), for which purpose the first package storage lift (6) is supplied by the second package storage lift (10) and the first package removal lift (7) supplies the second package removal lift (11). [2] Method according to claim 1, characterized by , that the first package storage lift (6) is pre-positioned on the target level to receive packages from the second package storage lift (10). [3] Method according to claim 1 or 2, characterized by , that the second package outbound lift (11) is pre-positioned on the source level to take over packages from the first package outbound lift (7). [4] Method according to any one of the preceding claims, characterized by , that the exchange of packages between the storage and retrieval machine (5) and the first package storage lift (6) or first package retrieval lift (7) takes place indirectly via buffer conveyors (12) which are arranged in the storage rack levels (3) adjacent to the package lifts (6, 7). [5] Method according to any one of the preceding claims, characterized by , that each lift (6, 7, 10, 11) is equipped with a vertically movable lifting platform (13), each of which is equipped with a conveyor that has space for one or two packages (P). [6] Method according to claim 5, characterized by that the vertically movable lifting platforms (13) are double-decker. [7] Method according to any one of the preceding claims, characterized by , that the lifts (6, 7, 10, 11) are arranged at one of the end faces of the storage rack aisles (2). [8] Method according to claim 7, characterized by , that the package storage lifts (6, 10) and the package removal lifts (7, 11) are each aligned with one side of a storage rack in a storage rack aisle (2). [9] Method according to any one of the preceding claims, characterized by that the lifts (6, 7, 10, 11) are identical. [10] Method according to any one of the preceding claims, characterized by , that at least one storage and retrieval machine (5) is provided per storage rack level (3). [11] Storage racking system for the sequenced storage and retrieval of packages into or from an associated rack storage unit (1) with a control unit (100), wherein the rack storage unit (1) comprises several storage rack aisles (2) and storage rack levels (3) with shelf compartments (4) for storing packages (P), and at least one storage and retrieval machine (5) per storage rack aisle (2) for the controlled storage and retrieval of the packages (P) into or from the rack compartments (4), and one controlled package infeed lift (6) and one controlled package outfeed lift (7) per storage rack aisle (2), each configured to convey or remove packages (P) to the respective rack level (3) and to deliver or receive packages (P) directly or indirectly to or from the storage and retrieval machine (5), wherein the storage racking system comprises an inbound conveyor (8) and an outbound conveyor (9) and the package inbound lift (6) connects to the inbound conveyor (8) and the package outbound lift (7) connects to the outbound conveyor (9), characterized by, that the storage racking system comprises a second controlled package infeed lift (10) and / or a second controlled package outfeed lift (11), wherein the second controlled package infeed lift (10) or the second controlled package outfeed lift (11) is arranged between the package infeed lift (6) and the infeed conveyor (8) and / or the package outfeed lift (7) and the outfeed conveyor (9), each configured to exchange packages in a controlled manner with the first package infeed lift (6) or first package outfeed lift (7), for which purpose the first package infeed lift (6) is supplied by the second package infeed lift (10) and the first package outfeed lift (7) is supplied in a controlled manner to the second package outfeed lift (11).

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