Fork prong moving system for storage

Abstract

A fork prong moving system for storage that comprises a vertical mast, a vertical carriage, a side carriage and extensible means. The vertical carriage is mechanically joined to the vertical mast and movable in a vertical direction along said mast. The side carriage is mechanically joined to the vertical carriage by mechanical means which are configured to enable the side carriage to move horizontally with respect to the vertical carriage. The extensible means are mechanically joined to the side carriage by a pivoting body which also defines a vertical direction such that said extensible means are rotatable in relation to the side carriage and concentrically around the vertical direction defined by the pivoting body.

Description

Field of the invention

[0001] The present invention relates to load handling systems used in industrial environments and storage warehouses. Specifically, the invention focuses on systems operating within aisles between storage racking rows, such as forklifts, trucks, and stacker cranes, which may be manually operated or fully automated.Background of the invention

[0002] In warehouse and industrial environments, load handling systems are employed to facilitate the storage and retrieval of goods. Common systems include forklifts, trucks, and stacker cranes, which may be manually operated or fully automated. Forklifts and trucks are generally used for handling loads, on pallets or hanging, through floor transportation. Stacker cranes, either floor rail-dependent or overhead traveling also serve as automated load storage and retrieval systems. Racking systems are the structures designed to house and stow loads, they can be designed, for example, for loads on pallets or loads on hanging structures.

[0003] Storage racking systems in warehouses are typically configured as single-deep or multiple-deep racking, with double-deep and triple-deep racking being the most common. The depth refers to how far a rack is from an access area, for example an aisle, for a given horizontal row of racks. For example, single-deep racking involves rack rows with unit loads one rack deep accessible from an aisle, while a double-deep racking would involve rack rows with unit loads up to two racks deep.

[0004] Double-deep and triple-deep racking requires specialized load handling equipment including accessories attached to the load lifting device, for example, extensions added on to lifting forks, where forks can be considered prong lifting mechanisms. Typical forks are designed to handle loads only one row deep. These extensions add length to the common forks enabling two row or three row deep load handling. Another option is to have forks that are longer than common forks. In any case, to maneuver these longer forks wider aisles are needed as compared to the width needed to maneuver common forks. Wider aisles make the use of space inefficient as they take up potential racking space. Width of an aisle is considered to be the horizontal distance defined by an aisle between opposite racks.

[0005] As such, there is an evident need for a load handling system for use along narrow aisles inside storage racking systems that can handle double-deep and triple-deep racking loads, where handling can be considered lifting, lowering and generally moving loads. Narrow aisles can be considered those with a minimum horizontal distance between opposite racks needed to maneuver common forks. Additionally, to improve load handling efficiency, there is needed a load handling system that can handle loads on either side of a rack aisle vertical row without need for repositioning elements of the load handling system designed to position it vertically to access different vertical rows of the racking system.Summary of the invention

[0006] Before describing the present invention, it is useful to understand the environment for which it has been designed, that is, racking systems. Racking systems can have single-deep rows, with one rack per row on either side of an aisle, double-deep rows, with two racks per row on either side of the aisle, triple-deep rows, with three racks per row on either side of the aisle. These rack rows can be stacked at different heights.

[0007] To address the identified needs, the present invention provides a fork prong moving system for storage as disclosed in claim 1.

[0008] Preferred embodiments of the aforementioned system are detailed in the dependent claims of claim 1.

[0009] As such, the provided system of the invention comprises, a vertical mast, a vertical carriage, a side carriage, and extensible means. The vertical carriage is mechanically joined to the vertical mast and movable in a vertical direction along said mast. The side carriage is mechanically joined to the vertical carriage by mechanical means which are configured to enable the side carriage to move sideways with respect to the vertical carriage. The extensible means are mechanically joined to the side carriage by a pivoting body which also defines a vertical direction such that said extensible means are rotatable in relation to the side carriage and concentrically around the vertical direction defined by the pivoting body.

[0010] The following three paragraphs will explain how the system of the invention according to the preceding embodiment solves the problem of maneuvering in narrow aisles, handling double-deep racking loads, and being able to access opposite sides of an aisle of a given vertical row without repositioning elements of the system of the invention designed to position it vertically. Narrow aisles can be considered those with a minimum horizontal distance between opposite racks needed to maneuver common forks.

[0011] Firstly, the system of the invention is able to, in a retracted position, fit in narrow corridors without needing to reposition the vertical carriage in order to handle loads, where handling is considered to be lifting, lowering and generally moving loads. The retracted position requires that the extensible means are retracted and that the side carriage and the pivoting body be disposed such that the extensible means do not project at all or project minimally beyond the horizontal limits that define the vertical carriage.

[0012] Secondly, the system of the invention is able to, in an extended position handle racking loads that are stowed up to two racks deep in a racking row. The extended position is achieved when the extensible means are extended and when the side carriage and the pivoting body are disposed with respect to the vertical carriage such that the extended extensible means project horizontally two racks deep in a racking row sufficiently to safely handle a double-deep racking load. In other words, horizontal movement of the side carriage towards the racking row by way of the mechanical means and then extension of the extensible means allow access to the double deep rack.

[0013] Thirdly, the system of the invention is able to, by way of the pivoting body and the mechanical means, handle racking loads that are stowed up to two racks deep in a racking row on either side of the aisle without need for repositioning the vertical carriage. The extensible means, by way of the pivoting body rotate about the side carriage thus enabling the extensible means to face opposite direction. The mechanical means and the extensible means then extend in order to access the double-deep racking load.

[0014] In an embodiment, the system of the invention comprises a side carriage that is mechanically joined to the vertical carriage by means of a telescopic guide such that the side carriage is capable of extending sideways away from the vertical carriage a distance defined by a section of the telescopic guide. The following paragraph will explain how this embodiment of the system of the invention solves the problem of moving in narrow aisles, handling triple-deep racking loads, and being able to access opposite sides of a same rack aisle vertical row without repositioning elements of the system of the invention designed to position it to access different vertical rows of the racking system. By having mechanical means that join the side carriage to the vertical carriage that are telescopic, the side carriage can extend horizontally at least one rack deep into a racking row. The telescopic means are configured to enable this one rack deep horizontal movement in opposite horizontal directions, that is the system can access three deep racks on either side of an aisle.

[0015] At this preferred embodiment, the telescopic guide is powered. In other preferred embodiments, the telescopic guide even could be manual drive.

[0016] In another embodiment of the system of the invention according to any of the embodiments thus far described, the fork prong moving system comprises measurement and dimensioning sensors configured to identify loads and to assist the movement of extensible means to handle loads.

[0017] In another embodiment of the system of the invention, according to any of the embodiments thus far described, the extensible means comprise at least one telescopic fork member. More preferably, the at least one telescopic fork member comprises, a fork body, an outside sleeve, a powered belt or chain, and a drive means, where the drive means are preferably connected to the measurement and dimensioning sensors as a safety feature to disconnect the drive means under predetermined sensor conditions (i.e., contacting obstacles). The outside sleeve runs along the fork body and the same outside sleeve is connected to the belt, preferably by a set of pins / bolts or similar; these are robust mechanical elements capable of withstanding cyclic loading. The belt is linked to the drive means so that said belt is moved by the drive means and as a result the outside sleeve is also moved, and this movement of the outside sleeve defines a longitudinal direction parallel to the extension of the telescopic fork member as a result of the drive mean actuation. Even more preferably, when connecting the outside sleeve to the belt with pins / bolts or similar, the drive means comprise a motor and a set of gears, wherein the motor drives the set of gears, the set gears drive the belt or chain, and the belt applies a force on at least a part of the set of pins which are located on the outside sleeve such that the outside sleeve can move longitudinally along an axis defined by the fork body.

[0018] Even more preferably yet, the at least one telescopic fork member is configured to have a maximum cross-sectional dimension, where said cross-section is taken in a plane perpendicular to the longitudinal direction of the extension, such that it can enter an introduce such fork member either into the opening of an enclosed, bottom closed, or an open pallet, or other similar load carrying means. Maximizing this cross-section can reduce vertical deflection and makes the telescopic fork member more robust.

[0019] In another embodiment of the system of the invention according to any of the embodiments thus far described, the extensible means extend in a direction perpendicular to a vertical plane. This is advantageous when the structure holding a load can be lifted when the extensible means extend in this manner.

[0020] In another embodiment of the system of the invention according to any of the previous embodiments the extensible means are connected by coupling means to the pivoting body such that the extensible means can move horizontally with respect to the pivoting body. Preferably, the coupling means are of the rack and pinion type or ball screw mechanism. By enabling horizontal movement of the extensible means with respect to the pivoting body the system can adapt the position of the extensible means to handle a variety of load bearing structures, for example, pallets with openings located at different widths.

[0021] In the following, there is a summary of the advantages the system of the invention provides over existing systems for stacking and retrieving loads from racking systems. The system of the invention: can be used to store and retrieve pallets and loads from multiple-deep storage racks, being able to access opposite sides of an aisle and from any shelf level of a given row, as a result of the multiple telescopic means, that is, the mechanical means and the extensible means. This combination of telescopic means provides storage optimization; is compatible and handles in an optimum manner closed-bottom pallets (pallets with bottom deckboards boarded on all four sides) when it incorporates two telescopic fork members thus providing storage optimization; it is able to pick, drop and handle fully enclosed (closed-bottom) pallets picking them over the bottom deckboards (instead of picking them from underneath), and equally being able to pick and handle open-bottom pallets in their transverse direction, thanks to the longitudinal extension mechanism of fork prongs without additional external support; is suitable for use with very narrow aisle storage racking systems (storage optimization), since when retracted or contracted, it requires minimal operating width to move through narrow aisles between racking rows; enhances sensor-based identification and measurement of load bearing structures (e.g. pallets), even in complex, multi-tiered racking scenarios. This is made possible by the integration of the multiple telescopic means, which allow introducing the measurement and dimensioning sensors inside the racking structure when retrieving load bearing structures (e.g. pallets) from the storage shelves, ensuring an optimal distance to the load bearing structure (e.g. pallet) front face for acquiring the required readings. effectively mitigates the deflection in the extensible means by incorporating the additional telescopic mechanical means, that is, the telescopic guide, that connect the vertical carriage with the side carriage. The telescopic guide has higher mechanical properties, minimizing the vertical displacement of the extensible means. This feature contributes to storage optimization and extends the operational lifespan of the extensible means. increases the overall operational speed or throughput when accessing multiple-deep storage racking row structures, by the concurrent and synchronized travel motion of the mechanical means (the telescopic guide) and the extensible means. The overall operational speed is enhanced, potentially doubling the operational throughput rate when retrieving or depositing load bearing structures from / to storage shelves. Brief description of the figures

[0022] The above and other advantages and features will be more fully understood following this detailed description of some example embodiments with reference to the attached drawings. These should be considered illustrative and not limiting. Fig. 1a is a perspective view of a fork prong moving system with extended extensible means for load bearing and a retracted side carriage. Fig. 1b is a perspective view of the fork prong moving system with extended extensible means for load bearing and an extended side carriage. Fig. 2 is a detailed perspective view of the extensible means for load bearing. Fig. 3 is a lateral view of the fork prong moving system handling a pallet at a first vertical level of a racking system. Fig. 4 is a lateral view of the fork prong moving system handling a pallet three rows deep and located at a second vertical level of a racking system. Fig. 5 is a perspective view of a disassembled telescopic fork member. Detailed description of the preferred embodiment

[0023] In the following detailed description, numerous specific details are presented in the form of examples to provide a thorough understanding of the relevant teachings. However, it will be apparent to those skilled in the art that the present teachings can be practiced without such details.

[0024] All the figures refer to a same embodiment of the present invention without this embodiment being limiting.

[0025] As seen in Fig. 1a and Fig. 1b, the illustrated embodiment provides a fork prong moving system, in the following system, configured to be connected to a vertical mast (not shown), where the system is configured to handle loads, where handling is considered to be lifting, lowering and generally moving loads. The system comprises a vertical carriage (1) which is connected to a vertical mast and movable vertically along it, a side carriage (2) attached to the vertical carriage (1) by means of a telescopic guide (5) which permits sideways movement of the side carriage (2) with respect to the vertical carriage (1).

[0026] At this preferred embodiment represented by the figures, the telescopic guide (5) is powered. In other preferred embodiments, the telescopic guide (5) even could be manual drive.

[0027] The system also comprises extensible means (3) which are connected to the side carriage (2) by means of a pivoting body (4) where the pivoting body (4) can rotate concentrically about a vertical rotation axis it defines which results in the extensible means (3) being able to rotate about the side carriage (2). In these figures we can also observe the extensible means (3) joined by coupling means to the pivoting body (4). These coupling means enable horizontal movement of the extensible means (3) with respect to the pivoting body (4) and they can be of the rack and pinion type (14) or ball screw mechanism. This horizontal movement can help adapt the system to lift a variety of load bearing structures.

[0028] Referring to Fig. 3, a lateral view of the embodiment, we can see the system in the aisle of a triple-deep row racking system (11) where the length of the vertical carriage (1) in a horizontal direction when it is disposed to handle rack loads is less than the horizontal length (width) of the aisle thus allowing the system to handle pallets in narrow aisles of racking systems without need to adjust the vertical carriage (1) position helping improve load handling efficiency. Narrow aisles can be considered those with a minimum horizontal distance between opposite racks needed to maneuver common forks.

[0029] We can also see that the telescopic guide (5) is fully retracted. The extensible means (3) are partially retracted and carrying a load (12) on a pallet (13). The side carriage (2) is disposed with respect to the vertical carriage (1) such that it is at a maximum distance from a first rack (111). In this position the pallet (13) and its load (12) are partially inside the first rack (111). If the extensible means (3) were to be fully retracted the pallet (13) and its load (12) would be contained in the horizontal limits (width) of the aisle (not shown). The telescopic guide (5) that connects the side carriage (2) and the vertical carriage (1) is configured to move the side carriage (2) both horizontally within the horizontal limits of the vertical carriage (1), and, also, extend it horizontally beyond the horizontal limits of the vertical carriage (1). In addition to this movement, the extensible means (3) are configured to extend horizontally, combining the movement of the telescopic guide (5) and the extensible means (3), the system is capable of handling pallets one rack deep up to three racks deep in a racking system (11) with the added advantage of not having to move the vertical carriage (1) position for any single-deep, double-deep and triple-deep rack load handlings, thus further improving efficiency. The pivoting body (4) allows the system to carry out single-deep, double-deep and triple-deep rack load handlings on either side of the aisle by rotating the extensible means (3) with respect to the side carriage (2) and then combining the movements of the telescopic guide (5) and extensible means (3) as previously described.

[0030] Referring to Fig. 4, a lateral view of the embodiment, we can see each extendible element of the system, that is, the telescopic guide (5) and the extensible means (3), extended in the same direction allowing the system to handle loads (12) placed on pallets (13) in a three deep row rack (113) of a vertical row of a racking system (11). Here we can see clearly how the vertical carriage (1) does not need to be repositioned in order to access the said rack (113).

[0031] Referring to Fig. 2, we can see how the extensible means (3) have been implemented in this embodiment. Firstly, the extensible means (3) comprise two telescopic fork members (6). Each telescopic fork member (6) comprises a fork body (7) and an outside sleeve (8). The outside sleeve (8) comprises a set of pins (10) configured to connect with a belt (9) configured to be driven by a set gears which are actuated by a drive means (a motor not shown). In Fig. 5, we can see a single disassembled telescopic fork member (6). In other embodiments, the drive means even could be manual.

[0032] Such as it may be deduced at the figures, the extended position of fork prongs to access and store racking loads up to two racks deep in a racking row can be achieved both either when extensible means (3) are extended by themselves and / or when the telescopic guide (5) is sideways extended so that the side carriage (2) is away from the vertical carriage (1), and also comprising a software control system to coordinate and synchronize the extensible means (3) and the telescopic guide (5). Even it may take place a simultaneous action of both mechanisms.Also, in different embodiments of the invention, the width between the telescopic fork members (6) may be varied and adjusted by mechanical means, and so can adapt to different pallets and loads.

Claims

1. A fork prong moving system for storage that comprises: - a vertical mast; - a vertical carriage (1); - a side carriage (2); and - extensible means (3), wherein: - the vertical carriage (1) is mechanically joined to the vertical mast and movable in a vertical direction along said mast; - the side carriage (2) is mechanically joined to the vertical carriage (1) by mechanical means which are configured to enable the side carriage (2) to move sideways with respect to the vertical carriage (1); - the extensible means (3) are mechanically joined to the side carriage (2) by a pivoting body (4) which also defines a vertical direction such that said extensible means (3) are rotatable in relation to the side carriage (2) and concentrically around the vertical direction defined by the pivoting body (4).

2. A fork prong moving system for storage according to claim 1 wherein the side carriage (2) is mechanically joined to the vertical carriage (1) by means of a telescopic guide (5) such that the side carriage (2) is capable of extending sideways away from the vertical carriage (1) a distance defined by a section of the telescopic guide (5).

3. A fork prong moving system for storage according to any of the previous claims, where the fork prong moving system comprises measurement and dimensioning sensors configured to identify loads and to assist the movement of extensible means (3) to handle loads.

4. A fork prong moving system for storage according to any of the previous claims wherein the extensible means (3) comprise at least one telescopic fork member (6).

5. A fork prong moving system for storage according to claim 4 wherein the at least one telescopic fork member (6) comprises: - a fork body (7); - an outside sleeve (8); - a powered belt (9) or chain; and - a drive means, wherein the outside sleeve (8) runs along the fork body (7) and the same outside sleeve (8) is connected to the belt (9), and the belt (9) is linked to the drive means so that said belt (9) is moved by the drive means and as a result the outside sleeve (8) is also moved, and this movement of the outside sleeve (8) defines a longitudinal direction parallel to the extension of the telescopic fork member (6) as a result of the drive mean actuation.

6. A fork prong moving system for storage according to claim 5 wherein the outside sleeve (8) is connected to the belt (9) by a set of metal pins / bolts (10) or similar.

7. A fork prong moving system for storage according to claim 6, wherein the drive means comprise: - a motor; - a set of gears, wherein the motor drives the set of gears, the set gears drive the belt (9) or chain, and the belt (9) applies a force on at least a part of the set of pins (10) which are located on the outside sleeve (8) such that the outside sleeve (8) can move longitudinally along an axis defined by the fork body (7).

8. A fork prong moving system for storage according to any claim 5 to 7 when depending on claim 3, wherein the measurement and dimensioning sensors are linked to the drive means.

9. A fork prong moving system for storage according to any of the previous claims wherein the extensible means (3) extend in a direction perpendicular to a vertical plane.

10. A fork prong moving system for storage according to any claim 5 to 9 when depending on claim 4, wherein the at least one telescopic fork member (6) is configured to have a maximum cross-sectional dimension, where said cross-section is taken in a plane perpendicular to the longitudinal direction of the extension, such that it can enter and introduce such fork member either into the opening of an enclosed, bottom-closed, or an open pallet, or other similar load carryings means.

11. A fork prong moving system for storage according to any claim 5 to 10 when depending on claim 4, wherein the width between the telescopic fork members (6) may be varied and adjusted by mechanical means.

12. A fork prong moving system for storage according to any of the previous claims wherein the extensible means (3) are connected by coupling means to the pivoting body (4) such that the extensible means (3) can move horizontally with respect to the pivoting body (4).

13. A fork prong moving system for storage according to claim 12 wherein the coupling means that connect the extensible means (3) to the pivoting body (4) are of the rack and pinion type (14) or ball screw mechanism.

14. A fork prong moving system for storage according to any claim 3 to 13 when depending on claim 2, wherein the telescopic guide (5) is powered.

15. A fork prong moving system for storage according to any claim 3 to 14 when depending on claim 2, comprising a software control system to coordinate and synchronize the extensible means (3) and telescopic guide (5), wherein the extended position of fork prongs row can be achieved both either when extensible means (3) are extended by themselves and / or when the telescopic guide (5) is sideways extended so that the side carriage (2) is away from the vertical carriage (1), or even it may take place a simultaneous action of both mechanisms.

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