High-bay warehouse for empty containers

Abstract

The invention relates to a high-bay warehouse for storing and retrieving containers, the high-bay warehouse comprising a plurality of separate rack bays which are arranged horizontally next to one another and vertically one above the other, and storage aisles which are arranged between groups of rack bays and extend in parallel with one another and in each of which at least one stacker crane is movable back and forth and is designed to move the containers vertically and horizontally and to move them into and out of the rack bays, the high-bay warehouse comprising, in addition to the separate rack bays, at least one region which is designed and suitable for receiving empty containers which are stacked one on top of the other. The invention further relates to a method for storing and retrieving as well as relocating containers in such a high-bay warehouse.

Description

[0001] HIGH-BAY WAREHOUSE FOR EMPTY CONTAINERS

[0002] 1 . Field of the invention

[0003] The invention relates to a high-bay warehouse for storing and retrieving containers and to a method for storing and retrieving or relocating containers in such a high-bay warehouse.

[0004] 2. State of the art

[0005] High-bay storage (HBS) is well-known in the art and is widely used, especially in transshipment facilities at sea or inland ports. High-bay storage typically comprises a multitude of separate rack compartments arranged horizontally next to one another and vertically one above the other, as well as storage aisles arranged parallel to one another between groups of rack compartments. Each of these aisles contains at least one reciprocating storage and retrieval machine, designed to move containers vertically and horizontally, as well as to move them into and out of the rack compartments.

[0006] An example of such a high-bay warehouse is disclosed in WO 2015 / 1243482 A1. In this high-bay warehouse, standard containers are picked up by a storage and retrieval machine at a transfer point within the high-bay warehouse. The storage and retrieval machine then transports them to a predetermined shelf compartment and stores them there. The containers are gripped from above while hanging and stored laterally in the respective shelf compartments using a telescopic system so that the long side of the container is aligned parallel to the storage aisle. This results in maximum space utilization within the high-bay warehouse, since the storage aisles only need to be slightly wider than the respective end faces of the containers.Furthermore, the suspended transport of containers using a storage and retrieval machine and the use of a telescopic system, which transports the containers from the storage aisle area to the desired shelf compartments, allows for the overall reduction of the high-bay warehouse structure. Shelves in the respective shelf compartments can be completely eliminated, provided that support points for at least the corner areas of the containers are provided in each shelf compartment. These supports can preferably be arranged on vertical supports of the high-bay warehouse structure itself, thus achieving the greatest possible lightweight construction of the high-bay warehouse structure while ensuring optimal space utilization.

[0007] When handling containers, especially in sea or inland ports, it is not only necessary to load and unload containers loaded with cargo; the handling of empty containers is also necessary. However, since empty containers do not need to be stored in separate or individual rack compartments within a high-bay warehouse, special storage areas for empty containers are usually provided near high-bay warehouses. In these storage areas, stacks of empty containers, typically 5-8 containers high, are formed. The loading and unloading of empty containers within these special storage areas can be carried out by specially designed vehicles, so-called "Empty Container Handlers" (ECHs).

[0008] In these areas, the containers are stacked directly on top of each other, new empty containers are placed on top of existing stacks if necessary, and required empty containers are removed from existing stacks in a circular process without it being necessary to remove a special container, as long as it is guaranteed that the desired size, quality and number of containers can be provided.

[0009] The handling of empty containers, as it is known to date, is therefore hardly automated and requires more effort than desired, both in terms of time and manpower. 3. Object of the invention

[0010] It was therefore an object of the invention to provide a high-bay warehouse and a method for storing, retrieving, or relocating containers in such a high-bay warehouse, which are suitable for overcoming the problems known from the prior art and achieving a higher degree of automation and safety as well as a higher turnover of empty containers per unit time. According to the invention, this object is achieved with a high-bay warehouse comprising the features of claim 1 and with a method comprising the features of claim 15. Advantageous embodiments of the invention are set forth in particular in the dependent claims.

[0011] 4. Summary of the invention

[0012] According to the invention, a high-bay warehouse for storing and retrieving containers is provided, which has a plurality of storage locations for containers arranged horizontally next to one another and vertically one above the other, between groups or levels of storage locations and running parallel to one another, in each of which at least one storage and retrieval machine is movable back and forth, wherein this storage and retrieval machine is designed to move the containers vertically and horizontally and to move them into and out of the storage locations. Such groups of storage locations are usually provided in a modular manner extending over almost the entire length and height of the rack warehouse. The storage locations are preferably provided as separately arranged shelf compartments and can thus also be accessed separately by at least one storage and retrieval machine in order to store or retrieve a container.The containers are thus accommodated in the rack compartments individually or, at half the standard length, at most in pairs, whereby sufficient space must be available above the containers for the operation of the storage and retrieval machine's conveying means, in particular telescopic systems with which the containers can be supported in a suspended position and moved perpendicular to the storage aisles into the rack compartments. According to the invention, the high-bay warehouse has at least one area that is designed and suitable for accommodating empty containers stacked on top of one another. In this area for empty containers, which according to the invention is located within the high-bay warehouse, no separate rack compartments are provided; instead, at least one area is provided that does not have the separate rack compartments otherwise provided for the containers.In this at least one area for empty containers, the empty containers can be stacked directly on top of each other and are still accessible by the storage and retrieval machines. A high-bay warehouse designed exclusively for empty containers is particularly preferred, thus ideally eliminating the need for separate shelving units instead of storage locations.

[0013] This ensures that, on the one hand, separate stacking areas outside the high-bay warehouse are not required, and, on the other hand, the handling of empty containers can be carried out automatically, preferably fully automatically, via the storage and retrieval machines within the high-bay warehouse.

[0014] In this context, it is preferred that the at least one area for empty containers comprises at least one horizontal row and / or one vertical row of storage locations or partial lengths thereof. It is particularly preferred in this context, for example, if the area for empty containers extends above a vertical row of separate shelf compartments, or is provided in a plurality of vertical rows above a row of separate shelf compartments.

[0015] However, it is particularly preferred if empty container areas extend on both sides of a storage aisle and the associated storage and retrieval machine is designed exclusively for the storage, retrieval, and relocation of empty containers. In this case, the at least one storage and retrieval machine within the storage aisle adjacent to the empty container areas can be designed so that it can move only one or, if necessary, several empty containers together. This creates a high-bay warehouse that optimally utilizes the resources intended for the respective purpose while using as little material as possible.

[0016] In this context, it is particularly preferred if the at least one area for empty containers is dimensioned such that it can accommodate at least three empty containers, preferably more than 15 empty containers, stacked on top of one another. In high-bay warehouses of this type, more than 10, preferably 11, separate shelf compartments for loaded containers are usually provided one above the other in each vertical row. Since in these vertical rows with separate shelf compartments the space required for the separate handling of the individual containers must remain between the individual containers, more empty containers can be provided within a corresponding vertical row of storage locations in an area for empty containers at the same height.Since the empty containers can be placed directly on top of one another in this area, the corresponding space within the high-bay warehouse can be used optimally, with at least one more container being able to be accommodated in a vertical row of empty containers than in a vertical row of separate shelf compartments intended for accommodating loaded containers.

[0017] It is preferred if the storage locations or separate racking areas are designed and suitable for accommodating a 20' standard container (1 TEU, Twenty Foot Equivalent Unit) or a 40' standard container (2 TEU), or for accommodating two half-length standard containers arranged one behind the other in the longitudinal direction. This means that two 20' standard containers adjacent to each other at their end faces can be placed in a storage location or separate racking compartment designed to accommodate a 40' standard container, or two 10' standard containers (0.5 TEU) can be stored in a storage location or separate racking compartment designed to accommodate a 20' standard container. This creates a high-bay warehouse that enables fully automated container handling while optimizing space utilization.

[0018] In this context, it is particularly preferred if at least two rows of storage locations, preferably shelf compartments, are arranged adjacently on both sides of each rack aisle ("double deep"), and if storage and retrieval machines can transport the containers into and out of the storage locations, preferably shelf compartments, using a telescopic system. This special handling and storage of containers also means that, with a suitable design of the telescopic systems on the storage and retrieval machines, two adjacent storage locations, preferably shelf compartments, can be served from each storage aisle on each side, thus a total of four storage locations, preferably shelf compartments ("double deep").

[0019] The number of storage aisles within such a high-bay warehouse can thus be further reduced, resulting in a high-bay warehouse with two horizontal and vertical rows of storage locations on the sides, followed by a first storage aisle, then four horizontal and vertical rows of storage locations, followed by a second storage aisle, and so on. This leads to optimal space utilization within the high-bay warehouse and a reduction in the number of storage aisles to the minimum required for the operation of the high-bay warehouse. Designing the high-bay warehouse as a "double-deep" high-bay warehouse is particularly suitable for handling empty containers or, in some cases, containers with only a light load.

[0020] In this context, it is particularly preferred if the storage and retrieval machine can move the containers into and out of the storage locations, preferably shelf compartments, with their long sides aligned parallel to the storage aisles. This results, on the one hand, in the arrangement of two rows of storage locations, preferably shelf compartments, on each side of a storage and retrieval machine, already described as preferred, being particularly advantageously supported. On the other hand, it also results in a minimal width of the storage aisles required for the storage and retrieval machines.

[0021] Unlike loaded containers, empty containers are stacked directly on top of one another. However, due to discontinuities in the corner areas of the containers, known as "corner castings," the stack may become unstable as the stack height increases. In the worst case, this may result in the entire stack or parts thereof tipping over, possibly into the aisle of the storage and retrieval machine. To overcome this problem, a preferred embodiment of the invention can provide retaining devices on the high-bay warehouse itself. In a particularly preferred embodiment of the invention, these retaining devices are mounted at regular intervals, preferably on both sides of the stack or the areas for empty containers. It is highly preferred if such retaining devices are horizontally arranged struts attached to the vertical uprights of the high-bay warehouse.

[0022] In this context, it is particularly preferred if these retaining devices, especially in the form of horizontal struts, are bevelled at the top and bottom so that the handling of the empty containers, which have to be lifted over the retaining devices during loading and unloading, is only minimally restricted and without risk of damage to the empty containers.

[0023] It is preferred that at least one storage aisle be arranged adjacent to two rows of empty container areas on either side, and that the stacker cranes can transport the empty containers into and out of the empty container areas using a telescopic system. This results in a high-bay warehouse that, with optimal space utilization, applies the same system used for handling loaded containers to the empty container area. This supports both the safe operation of the high-bay warehouse and the degree of automation of the handling of both loaded and empty containers.

[0024] In this context, it is particularly preferred if the high-bay warehouse is designed so that it can store more than 2500 standard containers per hectare (2500 TEU / ha), preferably more than 3000 TEU / ha, very preferably more than 5000 TEU / ha. The unit TEU per ha shown here represents a commercially available measure for the capacity of port logistics and in particular of high-bay warehouses. The stacking areas for empty containers outside of high-bay warehouses described above and operation with vehicles specially designed for this purpose, such as reach stackers, ECH or the like, achieve a space utilization of no more than 2500 TEU / ha. The high-bay warehouse according to the invention is able to increase the area for the handling of both loaded and empty containers, preferably in a fully automated manner, beyond this known measure.

[0025] According to a further aspect of the invention, a method for storing, retrieving, or relocating containers in a high-bay warehouse according to the first aspect of the invention described above is provided. Within this high-bay warehouse, the loaded containers are picked up by means of the storage and retrieval machines, transported to the respective shelf compartments, and stored therein, or, in the case of empty containers, stored in an area within the high-bay warehouse that is designed and suitable for receiving empty containers stacked on top of one another.

[0026] Preferably, the transport of containers, both loaded and empty, within the high-bay warehouse is fully automated. Empty containers are stacked on top of each other, preferably in designated areas within the high-bay warehouse, preferably vertical or horizontal rows of the high-bay warehouse, or parts of these rows, with optimal space utilization. In these areas, the empty containers are removed from the respective stack from above or placed on top of existing stacks of empty containers.

[0027] In this context, it is particularly preferred if groups of empty containers, preferably three empty containers stacked on top of each other and connected to each other, are picked up by means of a storage and retrieval machine, moved together within the high-bay warehouse and transported into or out of the area for empty containers.

[0028] It may also be preferable to provide horizontal intermediate beams in the empty container area, allowing these areas to be divided into at least two stacking areas for empty containers. This allows the stacking height for empty containers to be reduced using simple means without significantly affecting the storage capacity of these areas. 5. Brief description of the figures

[0029] The invention is explained in more detail below with reference to three figures, which illustrate preferred embodiments of the invention. The figures are not intended to limit the scope of the invention.

[0030] It shows:

[0031] Fig. 1 is a sectional side view of a high-bay warehouse according to the invention, which is designed exclusively for the storage of empty containers,

[0032] Fig. 2 is a top view of a high-bay warehouse according to the invention, which is designed exclusively for the storage of empty containers,

[0033] Fig. 3 is a sectional view of the front side of a high-bay warehouse according to the invention, which is designed exclusively for the storage of empty containers, and

[0034] Fig. 4 is a sectional view of the front side of a high-bay warehouse according to the invention, which is designed for the storage of both loaded and empty containers.

[0035] 6. Detailed description of the characters

[0036] Fig. 1 shows a sectional side view of a high-bay warehouse 1 with a plurality of vertical rows 9 and horizontal rows 8 of storage locations 15 for empty containers 7. Behind the illustrated area of ​​vertical rows 9 and horizontal rows 8 for empty containers 7, a storage and retrieval machine 5 is arranged in a storage aisle (not shown), which can move empty containers 7 from left to right and from top to bottom or in the opposite direction within the high-bay warehouse 1 and can store and retrieve them into and out of the respective storage locations 15. The empty containers 7 can be arranged in the vertical rows 9 shown here, stacked directly and immediately on top of one another without any spacing.The storage and retrieval machine 5 is capable of accessing any position within the rows 6a, 6b for empty containers 7, with empty containers 7 being regularly loaded starting from the bottom and retrieved starting from the top. If individual or all vertical rows 9 (not shown) have horizontally extending intermediate shelves, multiple stacks of empty containers can be formed in each row 9 and retrieved separately by the storage and retrieval machine 5.

[0037] Fig. 2 shows a top view of the high-bay warehouse 1 according to the invention from Fig. 1. The high-bay warehouse 1 is surrounded by transport routes 11a, 11b, via which the transport of empty containers 7 to and from the high-bay warehouse 1 can be effected. The transfer of empty containers 7 from the transport routes 11a, 11b into the high-bay warehouse 1 takes place via suitable transport devices 12, which are designed and equipped to exchange empty containers 7 between the transport routes 11a, 11b and the high-bay warehouse 1 and, in the case of empty containers 7 being stored, to remove them from vehicles 13 and transport them to the area of ​​storage and retrieval machines (not shown) within the storage aisles 4. There, the empty containers 7 are taken over by the storage and retrieval machines (not shown) which are movably arranged in the storage aisles 4 and are then transported by these to a suitable storage location 15 within the high-bay warehouse 1.

[0038] Fig. 3 shows a sectional end view of a high-bay warehouse 1 according to the invention, in which it can be seen that each storage aisle 4 and the storage and retrieval machine 5 arranged there are each assigned two vertical rows 9 of storage locations 15 arranged adjacent to each side. This arrangement of empty containers 7 within a high-bay warehouse 1, referred to as "double deep stacking", is made possible by the fact that each storage and retrieval machine 5 is assigned a telescopic system 14, by means of which the respective empty containers 7 can be transported in a hanging position into any position within the vertical rows 9 and into each storage location 15.In the case shown, this results (viewed from left to right) in an arrangement of two lateral vertical rows 9, followed by a storage aisle 4 with a storage and retrieval machine 5, followed by four vertical rows 9 of storage locations 15, in turn followed by a storage aisle 4 with a corresponding storage and retrieval machine 5 to the opposite side, finally followed again by rows 9 of storage locations 15 arranged one above the other. In the lower level of the high-bay warehouse 1, empty containers 7, which have been removed from the transport routes (not shown) by vehicles (not shown), are conveyed into the area of ​​the high-bay warehouse 1 by means of a transport device 12 in order to then be able to be picked up by the respectively assigned storage and retrieval machine 5.In the case of empty containers 7 being removed from the high-bay warehouse 1, the opposite procedure is followed: an empty container 7 is removed from the respective storage location 15 and the corresponding empty container 7 is placed on the transport device 12 in order to then be transported out of the high-bay warehouse 1 by this transport device 12.

[0039] Figure 4 shows a sectional view of an end face of a high-bay warehouse 1 according to the invention, with the sequence of a vertical row 9 of separate shelf compartments 3 for loaded containers 2 and a storage aisle 4, in each of which at least one storage and retrieval machine 5 is arranged. While each separate shelf compartment 3 has sufficient space 13 for the engagement of the telescoping system 14 of each storage and retrieval machine 5, the respective upper regions 6a, 6b of each vertical row 9 are designed such that at least three storage locations 15 arranged one above the other are provided for empty containers 7. These empty containers 7 can be stacked directly and immediately on top of one another in the regions 6a, 6b and can be gripped from bottom to top by the telescoping system 14 of the control retrieval machine 5 and removed from the regions 6a, 6b again from top to bottom.In the present embodiment, the supply of loaded containers 2 and empty containers 7 into the high-bay warehouse 1 takes place via a transport level 16 arranged below the level of the lowest control compartments 3, with transport devices 12 or transport paths 11 provided there for approaching a position below the storage and retrieval machine 5 by means of a suitable means of transport, such as a truck (not shown). The loaded containers 2 or empty containers 7 are then removed from the trucks (not shown) or the transport device 12 below the travel level 17 for the storage and retrieval machines 5 and lifted vertically upwards next to a corresponding shelf compartment 3 or next to the area 6a, 6b for empty containers 7.By means of the telescoping system 14, loaded containers 2 are then inserted laterally into the corresponding shelf compartments 3, or empty containers 7 are placed into the area 6a, 6b, if necessary placed on top of empty containers 7 already present there.

[0040] List of reference symbols

[0041] 1 high-bay warehouse

[0042] 2 containers

[0043] 3 shelves

[0044] 4 Lagergasse

[0045] 5 storage and retrieval machine

[0046] 6a Area for empty containers

[0047] 6b Area for empty containers

[0048] 7 Empty container

[0049] 8 Horizontal Row

[0050] 9 Vertical Row

[0051] 10 Vertical support

[0052] 11a Transport route

[0053] 11b Transport route

[0054] 12 Transport device

[0055] 13 Space for telescopic system

[0056] 14 Telescoping system

[0057] 15 storage space

[0058] 16 transport levels

[0059] 17 Driving level for storage and retrieval machine

Claims

Patent claims 1. High-bay warehouse (1) for storing and retrieving containers (2), comprising a plurality of storage locations (15) for containers (2) arranged horizontally next to one another and vertically one above the other, and storage aisles (4) arranged between groups of storage locations (15) and running parallel to one another, in each of which at least one storage and retrieval machine (5) is movable back and forth and which is designed to move the containers (2) vertically and horizontally and to move them into and out of the storage locations (15), wherein the high-bay warehouse (1) comprises at least one area (6) which is designed and suitable for receiving empty containers (7) stacked on top of each other.

2. High-bay warehouse (1) according to claim 1, characterized in that the storage locations (15) at least partially comprise separate shelf compartments (3).

3. High-bay warehouse (1) according to one of claims 1 or 2, characterized in that the at least one area (6) for empty containers (7) has the dimension of at least one horizontal row (8) and / or one vertical row (9) of storage locations (15) or separate shelf compartments (3) or partial lengths thereof.

4. High-bay warehouse (1) according to claim 3, characterized in that the at least one area (6) for empty containers (7) is dimensioned such that it can accommodate at least three empty containers (7), preferably more than 16 empty containers (7), stacked on top of one another.

5. High-bay warehouse (1) according to one of the preceding claims, characterized in that it is designed exclusively for receiving empty containers (7) is designed.

6. High-bay warehouse (1) according to one of claims 1 to 4, characterized in that it comprises more than 10, preferably 11, separate shelf compartments (3) arranged vertically one above the other in vertical rows (9) with separate Shelf compartments (3). High-bay warehouse (1) according to one of the preceding claims 1 to 6, characterized in that the vertical rows (9) of storage locations (15) can accommodate more than 14, preferably 16, empty containers (7). High-bay warehouse (1) according to one of claims 1 to 7, characterized in that the storage locations (15), preferably the separate shelf compartments (3), are designed and suitable for accommodating a 20-foot standard container (1 TEU) or a 40-foot standard container (2 TEU), or for accommodating two half-length standard containers (10-foot or 20-foot standard containers) arranged one behind the other in their longitudinal direction.High-bay warehouse (1) according to one of claims 1 to 8, characterized in that the storage aisles (4) are arranged on both sides adjacent to at least two rows (9a, 9b) of storage locations (15), preferably shelf compartments (3), and the storage and retrieval machines (5) can transport the containers (2, 7) into and out of the storage locations (15), preferably shelf compartments (3), by means of a telescopic system. High-bay warehouse (2) according to one of claims 1 to 9, characterized in that the storage and retrieval machine (5) can move the containers (2, 7) with their long sides aligned parallel to the storage aisles (4) into and out of the storage locations (15), preferably shelf compartments (3). High-bay warehouse (1) according to one of claims 1 to 10, characterized in that the storage and retrieval machine (5) can transport the containers (2, 7) in a suspended manner and supported from above.High-bay warehouse (1) according to one of claims 1 to 11, characterized in that the shelf compartments (3) each have supports at least for the. lower corners of the containers (2), preferably supports which are connected to vertical posts (10) of the high-bay warehouse (1). High-bay warehouse (1) according to one of claims 1 to 12, characterized in that at least one storage aisle (4) is arranged on both sides adjacent to two rows of areas (6a, 6b) for empty containers (7) and the storage and retrieval machines (5) can transport the empty containers (7) into and out of the areas (8) for empty containers (7) by means of a telescopic system. High-bay warehouse (1) according to one of claims 1 to 13, characterized in that the high-bay warehouse (1) is designed and suitable for handling more than 2500 TEU / ha, preferably more than 3000 TEU / ha, very preferably more than 5000 TEU / ha. High-bay warehouse (1) according to one of claims 1 to 14, characterized in that it is part of a transshipment facility, in particular of a seaport or intermodal terminal.Method for storing, retrieving, or relocating containers (2) in a high-bay warehouse (1) according to one of claims 1 to 15, characterized in that the containers (2) are picked up by means of the storage and retrieval machines (5), transported to the respective storage locations (15), preferably shelf compartments (3), and stored therein or, in the case of empty containers (7), stored in an area (6) that is designed and suitable to receive empty containers (7) stacked on top of one another. Method according to claim 16, characterized in that the containers (2) are moved with their long sides parallel to the storage aisles (4) both into and out of the storage locations (15), preferably shelf compartments (3), and into and out of the area (6) for empty containers (7). Method according to one of claims 16 or 17, characterized in that the transport of the containers (2, 7) within the high-bay warehouse (1) is fully automated. Method according to one of claims 16 to 18, characterized in that groups of empty containers (7), preferably three empty containers (7) stacked one above the other and connected to one another, are picked up by a storage and retrieval machine (5), moved together within the high-bay warehouse (1), and conveyed into or out of the area (6) for empty containers (7).

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