Storage system with a storage rack with several levels and method for operating for providing transport units from a storage facility on at least one retrieval route

Abstract

Storage system for transport units (T) with - a plurality of storage racks (R) with several storage rack levels (3) for storing the transport units (T), which have storage locations of at least twice the depth, with a storage rack aisle (2) located between the storage racks (R), - at least one automatic storage and retrieval device (5) which travels along each storage rack aisle (2), wherein the automatic storage and retrieval device (5) has means for carrying transport units (T) and load-carrying means for moving transport units (T) into storage locations of at least twice the depth and for retrieving transport units (T) from storage locations of at least twice the depth, and - at least one controller (10) for controlling the system and its components, wherein the controller (10) serves to control the automatic storage and retrieval device (5) such that the transport units (T) are deposited in a depth position at a storage location on the basis of a categorization of articles in the transport units (T).

Description

[0001] When picking or assembling orders from fully picked transport units such as items or containers, it is necessary to make the transport units belonging to the same order available in an organized or sorted manner. For this purpose, the transport units for an order are usually temporarily stored (buffered) until all the transport units required for the order are available. They are then transferred together to a collection line, which forwards them to palletizing, picking, goods issue, shipping, or the like.

[0002] A high-bay warehouse facility has an infeed or storage area through which goods are delivered and from which the stacker cranes pick up the goods for storage, the so-called pre-zone. Similarly, a retrieval area is required, where the stacker cranes deposit the goods after retrieval, and which is also assigned to the pre-zone. In automated order-picking warehouses, picking stations are usually located in the pre-zone. The pre-zone also houses the identification of goods for the inventory management system or material flow computer.

[0003] EP 1 964 792 B1 discloses a method for providing transport units from a storage facility in a desired order on at least one collection line. Rack and retrieval units in each warehouse rack aisle, retrieval lifts, and retrieval conveyors are controlled in such a way that they are coordinated with one another and loaded with goods so that they ultimately arrive sorted at the collection line or are delivered from it. Control and coordination are therefore relatively difficult and involve technical effort in the so-called pre-zone outside the actual shelves.

[0004] EP 2 741 977 A1 discloses a method for providing transport units from a storage facility to at least one retrieval route, wherein the transport units are stored in several storage racks and on several storage rack levels, wherein the inner storage racks are arranged in pairs adjacent to one another and a storage aisle is located on each side of the pair. At least one storage route and at least one retrieval route are provided. The transport units are stored and retrieved via a storage and retrieval device for each access aisle. A storage and retrieval device is provided for each access aisle. At least one retrieval lift is used to transfer the transport units to the adjoining retrieval route.A direct exchange of transport units between two adjacent storage racks takes place via cross conveyors in the storage racks from one access aisle to an adjacent access aisle. The storage and retrieval device moves the transport units in the cross conveyors.

[0005] US 2014 / 0124462 A1 discloses an automated multi-level warehouse comprising first and second storage racks having multiple rack levels and arranged to face each other parallel to each other, loading shuttle vehicles that can move horizontally between the storage racks and unload unit loads onto or off the racks, and a lifting device for moving the loading shuttle vehicles to different levels. The lifting device further comprises masts arranged next to the storage racks, a shuttle vehicle lifting platform arranged on the inside of the masts for upwardly transporting the shuttle vehicles, and unit load lifting platforms arranged on the outside of the masts for upwardly transporting the unit loads.When the shuttle lifting platform is aligned with the unit load lifting platforms, the loading shuttles on the shuttle lifting platforms can load unit loads from the shuttle lifting platform to or unload them from the unit load lifting platform. This allows unit loads to be transported even when the loading shuttles are moved upwards, eliminating the need to waste time waiting for unit loads. This makes it possible to achieve high performance. In this context, multi-level racking, as shown in the figure, can be used. Fig. 4, be divided into an upper and a lower part, with waiting platforms on each level in the lower part and no waiting platforms in the upper part or vice versa. Fig. In the embodiment shown in Figure 4, the upper part corresponds to the roaming-type automatic storage / retrieval system according to the first embodiment, and the lower part corresponds to the captive-type automatic storage / retrieval system in which a transfer shuttle vehicle is provided on each level. In this configuration, part of the automatic storage / retrieval system is of the roaming type, and slow-moving items are to be stored or retrieved in this portion, thus saving costs, and the remaining part is to be almost or entirely of the captive type, so that fast-moving items are to be stored or retrieved in this remaining portion, thereby maximizing throughput. Accordingly, this configuration is advantageous for a high-bay automatic storage / retrieval system and / or for an automatic storage / retrieval system for loads with varying storage and retrieval frequencies.

[0006] Therefore, it is an object of the invention to provide a storage system that combines the advantages of roaming shuttles and captive shuttles, but keeps roaming movement to a minimum.

[0007] This problem is solved by the features of claim 1.

[0008] By providing a transport unit storage system in which the controller is used to control the automatic storage and retrieval device so that the transport units are placed in a storage location in a depth position based on a categorization of items within them, it is possible to increase throughput in systems with the same space requirements and the same number of storage locations, or to maintain performance with a larger number of storage locations.

[0009] A minimal retrieval lead time leads to fewer conflicts between storage and retrieval devices and increases device utilization.

[0010] In addition, this can extend maintenance intervals and reduce power consumption and the number of device failures.

[0011] In a preferred embodiment, the controller serves to categorize articles in the transport units T as fast-moving, medium-moving, or slow-moving items based on their characteristics (see below).

[0012] In this application, categorization into fast, medium, and slow movers is based on the turnover rate at which the item / product is replaced. Fast-moving items are items that do not stay in the warehouse for long and leave it quickly again. Large quantities are handled in a short period of time. They are not stored for long, so they hardly take up any storage space and incur only low storage costs. Slow-moving items are items that are turned over slowly. They remain in the warehouse for a long time and take up storage space. Medium-moving items are items with a turnover rate that lies between that of fast and slow movers. The categorization into fast, medium, or slow movers can be done using an ABC analysis. The control system can be used to carry out the categorization dynamically.

[0013] The control system is advantageously used to control the automatic storage and retrieval device in such a way that it places fast-moving items at the front storage locations, medium-moving items at storage locations at double depth and slow-moving items at storage locations at triple depth (or deeper / deepest).

[0014] In other words, items with the highest turnover are stored in the most easily accessible location (the most forward storage location in terms of ASRS access). Items with the lowest turnover are stored in the least accessible location (the back). Items with medium turnover are stored in between.

[0015] The control can be used to perform the categorization on the following basis: - Product attributes (e.g. customer-specific data on product speed, e.g. urgency of the need), - Product status (e.g. reserve or active, dead stock and / or products excluded from shipping) - Loading unit status (e.g. unallocated stock, assignment of the loading unit to a specific order that is routed or routed and buffered at the destination aisle, etc., operation log (how often each product is removed within a certain period, see above)), - expected device resource consumption (e.g. ASRS) and / or - predicted product velocity (e.g. seasonal sales trend, promotion, obsolescence due to new product introduction, etc.).

[0016] All these factors can be used to train an artificial intelligence (AI) neural network, which could help the controller improve dynamic categorization.

[0017] In addition, the control can be used to distribute empty storage locations for each depth evenly over the storage aisle length, and a storage location is selected in the area that is closest to the next retrieval location and has the most empty locations.

[0018] To improve throughput, especially for fast-moving items, the control system can be used to select a storage location and storage depth that are close to a warehouse exit for the next items to be retrieved. This exit will be located near a removal system, such as a conveyor or lift, that transports transport units from the rack. Such a lift will have a vertically movable pallet truck for vertical transport and coupling to conveyors, preferably at each level to allow uncoupling from the automatic storage and retrieval system.

[0019] The system will preferably comprise one or more automatic storage and retrieval devices of the shuttle type, the unit load AS / RS type, the 2D shuttle type, the satellite system type, or a mixture thereof.

[0020] In a preferred embodiment, the storage system comprises the following: at least one storage lane, at least one retrieval lane, at least one retrieval lift used to transfer the transport units to the retrieval lane, at least one in-storage lift used to transfer the transport units from the at least one in-storage lane, preferably on each storage rack level, rack conveyors which couple the retrieval lift and the in-storage lift.

[0021] The invention also relates to a method for operating a storage system, in particular according to the above description, for storing transport units at storage locations of at least twice the depth, which are arranged in a plurality of storage racks with several storage rack levels for storing the transport units, wherein a storage rack aisle is located between the storage racks and at least one automatic storage and retrieval device is controlled such that it travels along each storage rack aisle, wherein the automatic storage and retrieval device has means for carrying transport units and load handling means for moving transport units into the storage locations of at least twice the depth and for retrieving transport units from the storage locations of at least twice the depth.In the method, the automatic storage and retrieval device is controlled to place the transport units in a depth position of a storage location based on characteristics of articles therein.

[0022] The invention minimizes moving / rearranging operations in the warehouse / shelves and ensures that the system can be operated efficiently.

[0023] Further details of the invention will now be explained with reference to the single figure, in which a schematic plan view of a possible embodiment of a storage system is shown.

[0024] The storage system is designated as a whole with 1 and enables storage of transport units, which are generally designated with T, in a plurality of storage racks R with several storage rack levels 3 for storing the transport units T, which have storage locations of triple depth. For the sake of clarity, Fig. 1 only the two left-hand racks R are shown with transport units T stored in the front, middle or rear in storage locations or positions of triple depth with respect to or in relation to the aisle 2.

[0025] Fig. Although Figure 1 shows only three aisles 2 with shelves, it is clear that a storage system can have any number of shelves R.

[0026] The storage racks R are arranged in pairs, with a storage rack aisle 2 between them. The inner racks R of each pair are arranged back-to-back, i.e., they abut or lie against each other. On each level 3 and in each aisle 2, an automatic shuttle-type storage and retrieval device 5 travels along the length of each storage rack aisle 2.

[0027] The loading units T can be trays, bags, containers, etc., which can be of the storage type, in which a product is stored that can be removed when orders are fulfilled. The loading units T can also be of the order type, in which a product is arranged or placed according to an order so that the order is at least partially fulfilled. They are usually removed from storage very quickly, so they have the characteristics of fast-moving items (as defined above).

[0028] Each storage rack level has rails on the opposite end faces of the storage racks R, on which at least one shuttle 5 can travel along the length of the aisle 2.

[0029] The storage racks have loading rails on which the load units T are placed. These rails are held between the travel rails on one side and longitudinal support rails on the other. The bars are arranged perpendicular to the longitudinal extent of the rack R (or aisle 2). Two (or more) bars hold each load unit T (e.g., tray) from below. The bars are arranged along the storage location of each rack R and each level 3.

[0030] The guide rails and the longitudinal support rails are attached to rack supports 13. Rack supports 13 either face aisle 2 or are located between racks R arranged back-to-back.

[0031] Every five levels, a maintenance platform is located in aisle 2, allowing maintenance personnel to access aisle 2, racks R, shuttles 5, etc., as needed.

[0032] In the present embodiment, the shuttles 5 have a carrying area for at least one load unit T, which is located between load handling means extending (on both sides) into the storage racks R in a direction perpendicular to the length of the aisle 2 for depositing or retrieving load units T into or from the storage racks R.

[0033] Load handling devices include telescopic rails which can be extended to either side of the support area and have contact elements which can be pivoted between an upright rest position and a horizontal operating position in which the contact elements contact the front of a load unit T when it is pushed into the shelves R or pulled out of the shelves R or onto the support area in a known manner.

[0034] Each shuttle 5 has a first set of four wheels for horizontal movement along the travel rails on the respective storage rack level 3 of an aisle 2. Two wheels per set on each side of the shuttle 5, with one or both on each side being driven by a motor via a common drive axle.

[0035] The storage system 1 has a storage lane 4 and a retrieval lane 6 for each aisle 2, which are connected to a retrieval lift 8A used to transfer the transport units T to the retrieval lane 6 and to a storage lift 8B used to transfer the transport units T from the at least one storage lane 4. The respective lanes will also be connected to or coupled to additional material handling systems of a warehouse, such as picking areas with GTP stations or packing stations, shipping areas, etc.

[0036] The rack conveyors 9, which preferably couple the outbound lift 8A and the inbound lift 8B on each storage rack level 3, can optionally be used to decouple the transport of the transport units T by the shuttles 5 from the transport by the lift 8A, B. Therefore, they are in Fig. 1 only indicated in the middle lane.

[0037] The rails for the shuttles 5 can run along the aisle 2 and thus provide the shuttle 5 with access to the rack conveyors 9 and / or the lifts 8A, B.

[0038] The system 1 has a main controller 10 for controlling the system and its components. The controller 10 serves to control the shuttles 5 for depositing the transport units T in a depth position (front, middle, or rear in the triple-deep warehouse) of a storage location based on a categorization of items in the transport units T.

[0039] The controller 10 is used to categorize articles in the transport units T as fast-moving items FM, medium-moving items MM or slow-moving items SM based on their characteristics in the transport units T.

[0040] Fast-moving items (FM), medium-moving items (MM), and slow-moving items (SM) are categorized based on the turnover rate at which the respective item / product is exchanged. Controller 10 is used to dynamically implement the categorization.

[0041] The control system is used to control the shuttles 5 in such a way that they deposit fast-moving items FM in front storage locations, medium-moving items MM in storage locations at double depth and slow-moving items SM in storage locations at triple depth.

[0042] In other words, the items with the highest turnover are stored in the most easily accessible location (the most forward storage location in terms of ASRS access). The items with the lowest turnover are stored in the least accessible location (the back). Items with medium turnover are stored in between.

[0043] The control 10 also serves to distribute storage location vacancies for each depth evenly over the storage aisle length, and a storage location is selected in the area with the most vacancy.

[0044] The control system is used to select a storage location 11 and a storage depth close to a conveyor 9 or lift 8B that takes transport units T out of the rack in order to improve throughput, particularly in the case of extremely fast-moving items. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] EP 1 964 792 B1

[0003] EP 2 741 977 A1

[0004] US 2014 / 0124462 A1

[0005]

Claims

[1] Storage system for transport units (T) with - a plurality of storage racks (R) with several storage rack levels (3) for storing the transport units (T), which have storage locations of at least twice the depth, with a storage rack aisle (2) being located between the storage racks (R), - at least one automatic storage and retrieval device (5) which travels along each storage rack aisle (2), wherein the automatic storage and retrieval device (5) has means for carrying transport units (T) and load-carrying means for moving transport units (T) into storage locations of at least twice the depth and for retrieving transport units (T) from storage locations of at least twice the depth, and - at least one controller (10) for controlling the system and its components, characterized bythat the control (10) serves to control the automatic storage and retrieval device (5) in such a way that the transport units (T) are deposited in a depth position at a storage location on the basis of a categorization of articles in the transport units (T). [2] Storage system according to claim 1, characterized by that the controller (10) serves to categorize articles in the transport units (T) as fast-moving, medium-moving or slow-moving on the basis of a product speed, on the basis of their features and / or a product attribute in the transport units (T). [3] Storage system according to claim 2, characterized bythat the control (10) serves to control the automatic storage and retrieval device (5) in such a way that it deposits fast-moving items closer to the aisle (2) and slow-moving items further away from the aisle (2) in depth at front storage locations, medium-moving items at storage locations at double depth and slow-moving items at storage locations at triple depth (or deeper / deepest). [4] Storage system according to claim 2 or 3, characterized by that the control (10) serves to carry out the categorization dynamically. [5] Storage system according to one of the preceding claims 2 to 4, characterized by that the controller (10) serves to carry out the categorisation on the following basis: - Product attributes, - Product status, - Loading unit status, - operating log, - predicted product speed and / or - expected device resource consumption. [6] Storage system according to one of the preceding claims, characterized by that the control (10) serves to distribute empty storage locations for each depth evenly over the length of the storage aisle, and a storage location is selected in the area with the most vacancy. [7] Storage system according to one of the preceding claims 2 to 6, characterized by that the control (10) serves to select a storage location and a storage depth that are close to an exit of the warehouse for the next articles to be retrieved. [8] Storage system according to one of the preceding claims, characterized by that the automatic storage and retrieval device (5) is of the shuttle type, the piece goods AS / RS type, the 2D shuttle type or the satellite system type. [9] Storage system according to one of the preceding claims, characterized by that it has the following: - at least one storage lane (4), - at least one removal track (6), - at least one retrieval lift (8A) used to transfer the transport units (T) to the retrieval track (6), - at least one storage lift (8B) used to transfer the transport units (T) from the at least one storage track (4), - Rack conveyors (9) which couple the outbound lift (8A) and the inbound lift (8B), preferably on each storage rack level (3), but not limited thereto. [10] Storage system according to one of the preceding claims, characterized by that the control (10) serves to select a storage location and a storage depth near a conveyor or lift that transports transport units out of the storage rack (R). [11] A method for operating a storage system, in particular according to one of the preceding claims, for storing transport units (T) at storage locations of at least twice the depth, which are arranged in a plurality of storage racks (R) with several storage rack levels (3) for storing the transport units (T), wherein a storage rack aisle (2) is located between the storage racks (R) and at least one automatic storage and retrieval device (5) is controlled such that it travels along each storage rack aisle (2), wherein the automatic storage and retrieval device (5) has means for carrying transport units (T) and load-carrying means for moving transport units (T) into the storage locations of at least twice the depth and for retrieving transport units (T) from the storage locations of at least twice the depth, characterized bythat the automatic storage and retrieval device (5) is controlled such that it deposits the transport units (T) in a depth position of a storage location on the basis of characteristics of articles in the transport units (T).

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