A storage container

Abstract

The disclosure relates to a storage container (502) for use in an automated storage and retrieval system. In the system, a plurality of the containers (502) can be stacked, one on top of another. The container comprises a body part (504) formed of a non-flammable material. The body part is arranged to hold goods for storage and retrieval. The container also comprises at least one reinforcing part (506) coupled to the body part and arranged to withstand the compressive load of containers stacked on top of the container and to transmit this load to structure below the container.

Description

TECHNICAL FIELD

[0001] The disclosure relates to a storage container. More particularly, it relates to a storage container for use in an automated storage and retrieval system.BACKGROUND

[0002] Traditional storage solutions usually involve the arrangement of goods on rows of shelves within a warehouse. The shelf location for each item is recorded in an inventory, and goods are retrieved from the shelves by a stock picker. The shelves are restocked and the inventory updated, as needed, as goods enter and leave the warehouse.

[0003] Warehouse workers may be assisted by robotic pickers and by automated inventory management systems. Automated transit systems may also be implemented in traditional warehouse set-ups to move goods from their inventory location to a picking and / or packing station.

[0004] An alternative to a traditional warehouse set-up is an automated storage and retrieval system in which robots retrieve items from their logged location within the warehouse and deliver the items to a packing station or port. Such systems can reduce or eliminate the space needed to pass between rows of shelves to access stock, thereby removing the need for broad aisles within the warehouse. One example of such a system involves placing goods in plastic bins or containers that are configured to be stacked on top of each other, and with stacks of the plastic containers arranged side by side, within a three-dimensional grid. A rail system is arranged on top of the grid, along which robotic container-handling vehicles configured to lift containers from the grid can travel. The container-handling vehicles are configured to transport containers from the grid and to deliver them to ports or stations at the periphery of the grid so that the goods within the container can be picked and packed.

[0005] In order to maximise the useful storage volume of the automated storage and retrieval system, it is desirable to increase the size of the three dimensional grid to fill as much of the warehouse as possible. This includes increasing the height of the grid to use as much vertical space as possible. However, while the existing plastic containers are strong enough and light enough to allow stacks up to 6m tall, at stack heights above that the load bearing down on the bottom container in the stack may be large enough to crush that container. Also, in the event of a fire, existing sprinkler systems may lose effectiveness with stacks of existing containers higher than 6m. For these reasons, 6m is currently a maximum height for stacks of containers in the automatic storage and retrieval system.

[0006] An alternative approach might be to use metal containers, which are more resistant to fire. This would allow existing sprinkler systems to maintain their effectiveness with stacks of containers over 6m. However, a metal container that can withstand the loading of a stack of containers on top of it higher than 6m would be prohibitively expensive and too heavy for handling by existing container-handling vehicles and other equipment of the system.

[0007] One or more aspects of the invention of the present application are set out in the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The disclosure will now be described in more detail in connection with a number of exemplary embodiments shown in the accompanying drawings, in which: Fig. 1 shows a perspective view of a storage system comprising a grid and a plurality of robotic container-handling vehicles configured to retrieve and / or rearrange goods stored within the grid; Fig. 2 shows a top view of the system of Fig. 1; Fig. 3A shows a side view of a first robotic container-handling vehicle suitable for use in the system of Fig. 1; Fig. 3B shows a side view of a second robotic container-handling vehicle suitable for use in the system of Fig. 1; Fig. 3C is a perspective side view of the robot of Fig. 3B; Fig. 3D is an underneath perspective view of the robot of Fig. 3B and Fig. 3C; Fig. 4 shows an existing computing device for implementing the operations described herein; Fig. 5 is a perspective view of a modified container that is for retrieving and rearranging by the robotic container handling vehicles, the modified container modified to embody this invention; Fig. 6 shows an exploded view of the modified container of Fig. 5, showing component parts of the modified container; Fig. 7 is a detailed view of a reinforcing part of the modified container; Fig. 8 is a perspective view of three of the modified containers in a stacked arrangement; and Fig. 9 is a perspective sectional view of two of the modified containers in a stacked arrangement. DETAILED DESCRIPTION

[0009] In overview, the disclosure relates to a modified container for use with an automated storage and retrieval system of the kind described hereinabove. The modified container is to be used in generally the same way as the unmodified container described above; that is, the modified container is for holding goods stored within the grid and is arranged so that several of the modified containers can be arranged in a stack. Also as described above, the modified container can be retrieved and rearranged by the robotic container-handling vehicles.

[0010] The modified container addresses drawbacks of existing containers by modifications that allow it to be arranged in stacks higher than 6m. This is done without risking the structural failure and collapse of the container at the bottom of the stack, without compromising the effectiveness of existing sprinkler systems in controlling and putting out a fire affecting the grid, without increasing the weight of the container so that it cannot be handled by existing robotic container-handling vehicles, and without prohibitively increasing the cost of the container.

[0011] In this embodiment, this performance by the modified container is achieved by: a body part of non-flammable material, such as thin sheet metal, that contains the goods to be held, but does not provide the structural strength of the container to support other containers on top of it; and a reinforcing part that reinforces the body part and does provide the structural strength to support other, like, modified containers in a stack on top of the modified container. By providing the body part of non-flammable material, such as metal, a fire within the modified container is less likely to spread from the container elsewhere, and a fire outside the modified container is less likely to spread inside the container. Thus, a stack higher than 6m can be achieved without compromising the effectiveness of existing sprinkler systems. As the body part does not provide the structural strength for stacking, it can be made of thin material, such as thin, sheet metal. Thus, the weight of the body part is minimised, which aids handling and also helps increase stack height. The reinforcing part provides the needed structural strength for stacking that the body part on its own lacks. As the goods are protected within the modified container by the body part, there is greater material choice over the reinforcing part and so a strong, light material can be chosen that does not necessarily need to be non-flammable (although it could be). Thus, the reinforcing part can sufficiently strengthen the modified container to allow stacks over 6m without increasing weight to a level that would hinder handling or cause the lowest container in the stack to fail. Plastic is used in this embodiment. In this embodiment a flange part is also provided and fixed to the bottom of the body part to help close the open top of the modified container below it in the stack to further guard against first spreading to or from the inside of the container and also to protect goods within the container from becoming wet and be being spoiled should a sprinkler system be set off.

[0012] A general description of the automated storage and retrieval system will now be given, with reference to Fig. 1 to Fig 4, by way of background to understanding the invention. The modified container will then be described with reference to Fig. 5 to Fig. 9.Automated storage and retrieval system overview

[0013] Referring to the embodiment shown in Fig. 1, a grid 100 comprises a frame formed by a plurality of generally rectilinear, adjacent vertical columns 102 formed between vertical frame members 104 and extending in the X and Y directions 108, 110. The grid elements may be fabricated of any appropriate material; for example, the frame members may be formed of extruded aluminium. Storage containers or bins 112 are stacked on top of each other, preferably in a self-supporting manner, in the Z direction 114 in the columns 102, forming a storage volume of storage cells for respective bins 112 extending in the X, Y and Z directions 108, 110, 114.

[0014] A rail system or network 116 is formed on top of the grid 100 and comprises pairs of vehicle rails or tracks 118a, 118b and 120a, 120b, respectively extending in the X and Y directions 108, 110. Robotic container-handling vehicles, or robots, 122, which can be of a range of size, shape and function, are provided and configured to run on the rails 118, 120 and to transport bins 112 in both the X and Y directions 108, 110. The robots 122 are additionally configured to lift and lower bins 112 from / into the columns 102 in the Z direction 114, the bins 112 optionally being guided by the vertical frame members 104. The robots 122 access the bins 112 via access openings 124 above the columns 102 and formed between the rails 118, 120.

[0015] Some columns 102 may be used for alternative purposes than bin storage. For example, port columns 126, 128 comprise port or access columns allowing transfer of a bin 112 in and / or out of the grid 100. Port columns 126, 128 provide a vertical channel for lifting of a bin 112 from, or lowering of a bin 112 to, a port or ports 130, 132. The ports 130, 132 are shown in Fig. 1 at the lowest level of the grid, however ports can be located at any vertical position along the column. The respective port columns 126, 128 can be assigned for removing ('drop-off) and / or returning or delivering ('pick-up') bins 112 from / to the grid 100. The ports 130, 132 are therefore configured to allow bins 112 to be removed and reintroduced (horizontally) into the associated port column. As such, a port 130, 132 can comprise a conveyor (not shown in Fig. 1) onto which a bin 112 may be lowered and transported horizontally out of the port column. The port columns 126, 128 include an opening or access point through which bins 112 can enter and leave the column.

[0016] Bins 112 can be transported along the top of the grid 100 to and / or from a port column 126, 128 by robots 122, and from a port 130, 132 to a location outside the grid 100, which may be an access station (not shown) for processing of the bin 112 or its contents, such as a picking station for adding content to, or removing content from, the bin 112. In alternative examples (not shown), the bin 112 may be transported to a port of another grid on the same or another level, or to an external facility. Transport of bins 112 to and from ports 130, 132 may be by any appropriate means (not shown) including conveyors, transport vehicles, lifts or robots.

[0017] Referring to the embodiment shown in Fig. 2, the X-Y configuration 200 of the rail system 116 can be seen in more detail, together with robots 202, 204 of different types. The rail system includes rails 206 defining between them vertical column access openings 124 for access to bins 112. The rails 206 can be any appropriate type for permitting travel of the robots 202, 204 in the X and Y directions 108, 110 thereon, including (not shown) groove-type rails for receiving vehicle wheels, or protrusion-type rails for engaging wheel recesses. Each rail 206 may comprise a single track or multiple parallel tracks in each of the X and Y directions 108, 110.

[0018] A first, 'cantilever' type of robot 202 is shown in more detail in Fig. 3A and includes a body 300, a set of wheels 302 and a lifting device 304. The body 300 contains operational equipment (not shown) for the robot 202 including drive, power and control systems. The wheels 302 permit movement of the robot 202 in one of the X and Y directions, an additional set of wheels (not visible in this view) permitting movement in the other of the X and Y directions, in both cases along the respective rails or tracks 206. One or both sets of wheels can be raised or lowered to permit selective engagement of the rails for movement in the desired direction. The lifting device 304 includes a cantilever element 306 extending in the X-Y plane from the top of the body 300, and a gripping device 308, which is raisable and lowerable from the cantilever element 306. The gripping device 308 is configured to grip or engage a bin 112; for example, by gripping a part of the bin 112, or by passively or actively engaging a suitably configured part of the bin 112.

[0019] A second, 'internal cavity' type of robot 204 is shown in more detail in Fig. 3B and includes, as an alternative to the cantilevered lifting system, an internal cavity 310 within the body 300 and in which the lifting device 312 including a gripping device (not shown) is located. In this case, the body 300 includes the robot's operational equipment and a storage space for one or more bins 112, for use, for example, while transporting the bin 112.

[0020] Fig. 3C shows a perspective side view of the robot of Fig. 3B in which the first set of wheels 302 from Fig. 3B are visible. The additional set of wheels referenced above but not shown in Fig. 3B are shown as wheels 303 in Fig. 3C. The additional set of wheels 303 is arranged perpendicular to the first set of wheels 302, to allow rolling of the robot 204 in the X and Y directions on the first and second set of wheels 302, 303 respectively. The first and second set of wheels 302, 303 shown in Fig. 3C may be configured to be independently lowered into engagement with the rails (and conversely raised out of engagement with the rails) to allow the robot 202 to move in the X and Y direction across the arrangement of rails shown in Fig. 2. Although the perspective view shown in Fig. 3C is of the robot 204 of Fig. 3B, it will be appreciated that a similar perpendicular wheel arrangement may be applied to the robot 202 of Fig. 3A.

[0021] Fig. 3D shows a perspective view of the internal cavity type of robot 204 shown in Fig. 3C. The gripping device 350 of the robot 204 can be seen in Fig. 3D and will now be explained. With continued reference to Fig. 3D, the gripping device 350 includes a platform 352 extending in the X and Y plane and that is rectangular when viewed in the Z direction. The gripping device 350 also includes a plurality of engagement fingers in the form of four location fingers 354 and four pairs of latching fingers 356.

[0022] Each of the location fingers 354 is a downwardly projecting spike, projecting from the platform 352 in the Z direction and mounted at a respective corner of the platform 352. The location fingers 354 are sized, shaped and positioned to slide over and locate the corners of a bin 112 when the gripping device 350 is lowered to a bin 112 to engage it for lifting. When so engaged, an outside surface of each bin corner abuts a respective one of the location fingers 354, thereby being located relative thereto in the X-Y plane.

[0023] Each pair of latching fingers 356 has a downwardly projecting portion projecting in the Z direction with a sideways projecting portion on the end of each finger of the pair. The sideways projecting portions of each pair project away from each other in the X-Y plane. The latching fingers 356 are sized, shaped and positioned to be inserted in an aperture formed in structure of the bin 112 when the gripping device 350 is lowered to the bin 112 to engage it for lifting. The latching fingers are also arranged to be operated to pivot the latching fingers 356 of each pair apart so that the sideways projecting portion of each pair moves apart to latch around cooperating structure (not shown) of the bin 112, thereby engaging the bin 112 for lifting with the gripping device 350 by operating the lifting device 312.

[0024] Fig. 3D shows elongate flexible members 360 of the lifting device 312. The elongate flexible members 360 are four cables 360. A respective cable 360 is anchored to the platform 352 of the gripping device 350 towards each corner of the platform 352. The other end of each cable 360 is connected to structure (not shown) of the lifting device 312 for winding in and winding out the cables 360, thereby raising and lowering the gripping device 350 and any bin 112 with which it is engaged.Control and monitoring system

[0025] Control and monitoring of the automated storage and retrieval system, including monitoring and storing bin position and controlling bin delivery, retrieval and transport and robot routing and collision avoidance, is performed by a control system shown in Fig. 4 in communication with the robots and / or other controllable system components. Control can be performed locally or remotely and may be implemented by a processing system, for example in the form of a computing device. Accordingly, the methods described herein may form all or part of a computer-implemented method, or a system configured to perform the methods described herein.

[0026] With reference to Fig. 4, a processing system 400 suitable for carrying out the methods described herein will now be described. Fig. 4 shows a block diagram of one implementation of a processing system 400 in the form of a computing device within which a set of instructions for causing the computing device to perform any one or more of the methods described herein may be executed. In some implementations, the computing device may be connected (e.g., networked) to other machines in a Local Area Network (LAN), an intranet, an extranet, or the Internet. The computing device may operate in the capacity of a server or a client machine in a client-server network environment, or as a peer machine in a peer-to-peer (or distributed) network environment. The computing device may be a personal computer (PC), a tablet computer, a set-top box (STB), a Personal Digital Assistant (PDA), a cellular telephone, a web appliance, a server, a network router, switch or bridge, or any machine capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that machine. Further, while only a single computing device is illustrated, the term `computing device' shall also be taken to include any collection of machines (e.g., computers) that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methods described herein.

[0027] The example processing system 400 includes a processor 402, a main memory 404 (e.g., read-only memory (ROM), flash memory, dynamic random-access memory (DRAM) such as synchronous DRAM (SDRAM) or Rambus DRAM (RDRAM), etc.), a static memory 406 (e.g., flash memory, static random-access memory (SRAM), etc.), and a secondary memory (e.g., a data storage device 418), which communicate with each other via a bus 430.

[0028] Processor 402 represents one or more general-purpose processors such as a microprocessor, central processing unit, or the like. More particularly, the processor 402 may be a complex instruction set computing (CISC) microprocessor, reduced instruction set computing (RISC) microprocessor, very long instruction word (VLIW) microprocessor, processor implementing other instruction sets, or processors implementing a combination of instruction sets. Processor 402 may also be one or more special-purpose processors such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), network processor, or the like. Processor 402 is configured to execute the processing logic (instructions 422) for performing the operations and steps described herein.

[0029] The processing system 400 may further include a network interface device 408. The processing system 400 also may include any of a video display unit 410 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)), an alphanumeric input device 412 (e.g., a keyboard or touchscreen), a cursor control device 414 (e.g., a mouse or touchscreen), and an audio device 416 (e.g., a speaker).

[0030] It will be apparent that some features of the processing system 400 shown in Fig. 4 may be absent. For example, the processing system 400 may have no need for display device 410 (or any associated adapters). This may be the case, for example, for particular server-side computer apparatuses which are used only for their processing capabilities and do not need to display information to users. Similarly, user input device 412 may not be required. In its simplest form, processing system 400 comprises processor 402 and main memory 404.

[0031] The data storage device 418 may include one or more machine-readable storage media (or more specifically one or more non-transitory computer-readable storage media) 428 on which is stored one or more sets of instructions 422 embodying any one or more of the methods or functions described herein. The instructions 422 may also reside, completely or at least partially, within the main memory 404 and / or within the processor 402 during execution thereof by the processing system 400, the main memory 404 and the processor 402 also constituting computer-readable storage media 428.

[0032] The various methods described herein may be implemented by a computer program. The computer program may include computer code arranged to instruct a computer to perform the functions of one or more of the various methods described herein. The computer program and / or the code for performing such methods may be provided to an apparatus, such as a computer, on one or more computer-readable media or, more generally, a computer program product. The computer-readable media may be transitory or non-transitory. The one or more computer-readable media could be, for example, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, or a propagation medium for data transmission, for example for downloading the code over the Internet. Alternatively, the one or more computer-readable media could take the form of one or more physical computer-readable media such as semiconductor or solid-state memory, magnetic tape, a removable computer diskette, a random-access memory (RAM), a read-only memory (ROM), a rigid magnetic disc, or an optical disk, such as a CD-ROM, CD-R / W or DVD.

[0033] The computer program is executable by the processor 402 to perform functions of the systems and methods described herein.

[0034] In an implementation, the modules, components, and other features described herein can be implemented as discrete components or integrated in the functionality of hardware components such as ASICS, FPGAs, DSPs, or similar devices.

[0035] A 'hardware component' is a tangible (e.g., non-transitory) physical component (e.g., a set of one or more processors) capable of performing certain operations and may be configured or arranged in a certain physical manner. A hardware component may include dedicated circuitry or logic that is permanently configured to perform certain operations. A hardware component may be or include a special-purpose processor, such as a field programmable gate array (FPGA) or an ASIC. A hardware component may also include programmable logic or circuitry that is temporarily configured by software to perform certain operations.

[0036] Accordingly, the phrase 'hardware component' should be understood to encompass a tangible entity that may be physically constructed, permanently configured (e.g., hardwired), or temporarily configured (e.g., programmed) to operate in a certain manner or to perform certain operations described herein.

[0037] In addition, the modules and components can be implemented as firmware or functional circuitry within hardware devices. Further, the modules and components can be implemented in any combination of hardware devices and software components, or only in software (e.g., code stored or otherwise embodied in a machine-readable medium or in a transmission medium).Operation of the automated storage and retrieval system

[0038] In operation, each bin 112 is given a unique identifier, which maybe marked on the bin 112 using a computer-readable identifier (e.g., a barcode, quick-response code or radio-frequency identification tag) to ease identification of the bin 112. A database of the processing system 400 stores, in association with the unique identifier, the position and, optionally, content of each bin 112. When a bin 112 is moved (e.g., when it is retrieved from the grid 100), the database is updated to record its change in position.

[0039] When it is desired to retrieve a bin 112 from the grid 100, under control of the processing system 400, a robot 202, 204 is routed via the rail system 116 to the vertical column 102 including the storage cell where, according to the database, the bin 112 is positioned, and the lifting device 304, 312 is positioned (according to robot type) over the corresponding access opening 124, either adjacent or below the robot 202, 204. The robot 202, 204 lowers the gripping device 308 which engages, grips and lifts the bin 112 to the robot 202, 204. The robot 202, 204 then transports the bin 112, for example, to the drop-off port column 126, 128 for delivery to the port 130, 132 and subsequent processing external to the grid 100. In the event that the target or designated bin 112 is below other bins in the stack then the robot 202, 204 or multiple robots, which may be dedicated to the task, are controlled in a 'digging' operation to sequentially lift and reposition, temporarily or permanently, bins above the target bin 112 in order for it to be retrieved. It will be appreciated that other operations in relation to the bin 112 can be carried out in a similar manner. For example, a bin 112 can be delivered for storage in the grid 100 at the port 130, 132 of the pick-up port column 126, 128, gripped and lifted by a robot 202, 204 and delivered to the desired storage cell, bins above the desired position being repositioned if necessary as discussed above.Description of specific improvements

[0040] As can be seen in Fig. 5, the modified container, which will also be referred to as the modified bin 502 is made up of a body part 504, four reinforcing parts 506 (only two of which are visible in Fig. 5) and a flange part 508.

[0041] The body part 504, when the bin 502 is positioned as it would be in use for containing goods, has four generally vertical walls 510 at right angles and a base 512 (visible in Fig. 8). In other words, the walls extend in the z direction and the base lies in the x-y plane. The walls 510 and base 512 are integrally formed and so are joined to each other at their edges where they meet so as not to have holes or gaps between or in them (except as will be described below). Thus, the body part 504 is an open-topped receptacle for goods that is sealed, except for that open top. The body part 504 further includes an outwardly-projecting lip 505 around its upper edge.

[0042] The four reinforcing parts 506 are fixed to the outside of the bin, spaced apart and, when the bin is positioned as it would be in use for containing goods, extend from the top of the bin 502 to its base.

[0043] The flange part 508 is fixed to the bottom of the bin 502 and extends out from the bin, in a generally horizontal direction, all around the bottom of the bin 502.

[0044] More details of each of these components will now be described with reference to Fig. 6, which shows the body part 504, the reinforcing parts 506 and the flange part 508 spaced apart from each other before assembly.

[0045] With continued reference to Fig. 6, in this embodiment the body part 504 is formed of 0.5mm thick sheet steel. It is envisaged that the body part 504 is formed from this material using existing techniques. The body part 504 is formed to have reinforcing features in the form of three box-profile ribs 514 in each wall 510, extending the height of each wall 510.

[0046] The reinforcing parts 506 are each the same as each other. One 506 will now be described with reference to Fig. 7, it being understood that this description is representative of all four reinforcing parts 506. The reinforcing part 506 is formed of plastic. It serves as a column to support the load of others of the modified bin 502 stacked above it and to transfer that load to others of the modified bin stacked below it, or to the base of the grid if the modified bin 503 is the lowest bin of the stack. The reinforcing part 506 is generally a u-section column with additional reinforcement. The u-section is formed of (1) a web 516 that lies face-to-face against one of the walls 510 of the body part 504 when the reinforcing part 506 is fixed thereto, and (2) a flange 518 at each edge of the web 516 and perpendicular thereto so that they project from the wall 510 of the body part 504 to which the reinforcing part 508 is fixed. The additional reinforcement is provided by a series of cross braces 520 between the flanges. The reinforcing part 506 is formed as a single piece and so the web 516, flanges 518 and cross braces 520 are all integrally formed and connected to each other.

[0047] The reinforcing part 506 further includes a foot 522 at the bottom of each flange 518. When the reinforcing part 506 is fixed to the body part 504, each foot 522 projects towards the body part 504 and is shaped and configured to extend beneath the base 512 so that the top of each foot 522 abuts the base 512. As will be seen, this supports and lifts the body part 504 when the container 502 is engaged and lifted by a robot, such as those 202, 204 described above with reference to Figs. 1-4.

[0048] With continued reference to Fig. 7, the reinforcing part 506 further includes two shoulders 524, each extending in a horizontal plane from the top of the web 516 a the top of a respective one of the flanges 518. Each shoulder 524 has a spigot 526 that projects upwardly from it.

[0049] With reference to Fig. 6, the flange part 508 is a generally rectangular frame. It is also formed of 0.5mm thick sheet steel. The flange part 508 has an inner portion 528 and an outer portion 530. The inner portion 528 is shaped and configured for fitting face-to-face against the base 512 of the body part 504 so that it extends around the permitter of that base 512. The outer portion 530 extends outwards from the inner portion, and so outwardly from the base 512 of the body part 504 when fitted to it, in a horizontal plane. The flange part 508 includes a transition between the inner portion 528 and the outer portion 530 so that the two portions are vertically displaced from each other, the outer portion being lower.

[0050] With continued reference to Fig. 6, the modified bin 502 is assembled by fixing firstly all four of the reinforcing parts 506 to the body part 504, and then fixing the flange part 508 to the body part 504. How this is done will now be described.

[0051] Each reinforcing part 506 is fitted to the body part 504 by inserting the two spigots 526 of the reinforcing part through cooperating holes in the rim 505 of the body part 504. This locates the top of each reinforcing part 506 relative to the body part 504. The bottom of each reinforcing part 506 is then moved towards the body part 504 so that the web 516 of each lies against one of the walls 510 of the body part 504, and so that the feet 522 of each reinforcing part 506 extend underneath and abut the base 512 of the body part 504. Thus the feet 522 act as a body-part-engaging portion of the reinforcing part 506.

[0052] The flange 508 is then fitted against the base 512 of the body part 504. Cut outs 532 in the inner portion 528 and in the transition of the flange 508 accommodate the feet 522 of each reinforcing part 506 and locate the bottom of each reinforcing part 506 relative to the flange 508 and relative to the body part 504. The flange 508 is spot welded to the base 512 of the body part 504 to secure all the components together. Thus, the modified bin 502 is assembled. It should also be noted that the flange 508 includes a pair of semi-circular cut-outs 534 in the outer edge of the outer portion 530 of the flange 508. The purpose of these will later be made clear when use of the modified bin 502 is described.

[0053] Use of the modified bin 502 will now be described with reference to Fig. 8 and Fig. 9. Fig. 8 shows three of the modified bins 503 stacked on top of each other. When stacked, the various components and features of each bin 503 cooperate with those of the bin 502 above and the bin 502 below.

[0054] Firstly, as can be seen in Fig. 8, the reinforcing parts 506 are arranged above each other to form load-bearing columns to take the weight of the bins 502 in the stack and transmit this to the base of the grid. More particularly, the shoulders 524 of each reinforcing part 506 abut up against the underside of the rim 505 of the body part 504, which in turn abuts up against the outer portion 530 of the flange 508 of the bin 502 above. (Thus, for each of the bins 502, the rim 505 acts as upper interface structure and the flange 508 acts as lower interface structure.) At the other end of the reinforcing parts 506, the bottom of the feet 522 abut down against the upper side of the outer portion 530 of the flange 508 of the bin 502 to which they are fitted. When stacked, the spigots 526 of the lower bin 502 fit inside the semi-circular cut-outs 534 in the outer edge of the flange 508 of the upper bin 502.

[0055] Also, as can be seen in Fig. 8, the flange 508 closes an annular gap that would otherwise exist between upper and lower bins 502. This can be seen more clearly in the sectional view of Fig. 9. Here it can be seen that the inner portion 528 of the flange 508 is fixed face-to-face to the underside of the base 512 of the upper bin 502 and creates a seal with that base 512. It can also be seen that the outer portion 530 of the flange 508 lies on top of and in face-to-face contact with the rim 505 of the lower bin 502, creating a seal with that bin 502. Thus, each bin 502 is closed when beneath another 502 in a stack. Fig. 9 also shows how the transition between the inner portion 528 and outer portion 528 of the flange 508 vertically displaces these two portions to accommodate the feet 522 of the reinforcing parts 506.

[0056] None of the figures shows the modified bin 502 being engaged by a robot 202, 204 for lifting. It is envisaged that the modified bin 502 be engaged and lifted in the same way as existing bins, such as those 112 described above with reference to and as shown in Figs. 1 to 4. Specifically, the upper portion of each of the reinforcing parts 506 of the modified bin 502 is shaped and configured to be engaged by the latching fingers 356 latching underneath the shoulders 524 so as abut an underside of those shoulders. Thus, the latching fingers 356 can be raised up by the robot 202, 204 to which they are attached to lift the reinforcing parts 506 and hence the modified bin 502.Additional disclosure

[0057] In a first aspect of this invention, there is provided a storage container for use in an automated storage and retrieval system, in which system a plurality of the containers can be stacked, one on top of another, the container comprising: a body part formed of a non-flammable material, the body part arranged to hold goods for storage and retrieval, at least one reinforcing part coupled to the body part and arranged to withstand the compressive load of containers stacked on top of the container and to transmit this load to structure below the container.

[0058] The plurality of the containers may each be substantially the same as the container. For example, the plurality of containers may be made to the same design, the same specification and in the same way as the container. There may be some insubstantial differences between ones of the containers due to normal manufacturing variation.

[0059] The structure below the container may be structure of another container on which the container is stacked. The structure below the container may be a base of the system on which the lowest container in a stack rests.

[0060] The body part may comprise a base and sides that form the base and sides of the container. The base and sides of the body part may form a substantially continuous enclosure. By avoiding holes or other gaps in the base and sides, this helps to avoid a fire in the container spreading outside the container; it also helps avoid a fire outside the container spreading inside the container. It also guards against water from a sprinkler system entering the container and spoiling goods in the container in the event that a fire triggers operation of the sprinkler system.

[0061] The body part may comprise an open top that is also an open top of the container. The open top of the container may be at least partly closed by the base of another of the containers when stacked on top of the container.

[0062] The body part may be arranged not to transmit the load of containers stacked on top of the container to structure below the container. The body part may fail if, without the reinforcing part coupled to it, other containers with goods inside them are stacked on top of the container.

[0063] The body part may be formed of sheet material. It may be formed of sheet metal, for example steel. It may be formed of thin sheet metal. The sheet material and / or the thickness of the body part may be less then 1mm thick. It may be between 0.25mm and 0.75mm thick. It maybe 0.5mm thick.

[0064] The reinforcing part may be of a flammable material. The reinforcing part may be outside the body part when coupled thereto. Should the reinforcing part catch fire, it is therefore less likely to set fire to goods within the body part and can more easily be accessed and doused by a sprinkler system. The reinforcing part may be inside the body part when coupled thereto.

[0065] The reinforcing part may be coupled to the body part so as to abut interface structure of the container. The interface structure may be structure of the body part. The interface structure of the container may be structure arranged to abut the interface structure of another container. The container may have upper interface structure and lower interface structure. The upper interface structure may be a lip projecting from the upper periphery of the body part, for example around the open top. The lower interface structure may be the flange part. The reinforcing part may extend between the two interface structures and abut each. When stacked, the upper interface structure of the container may abut the lower interface structure of another container stacked on top of the container, and the lower interface structure of the container may abut the upper interface structure of a further container stacked below the container. In this way, the reinforcing part acts as a compressive support. In other words, the reinforcing part acts as a column.

[0066] As well as withstanding the compressive load of containers stacked on top of the container, the at least one reinforcing part may also be coupled to the body part to lift the body part and arranged to withstand the tensile load of lifting the body part. The reinforcing part may comprise a body-part-engaging portion to engage and support the body part during lifting. The body-part-engaging portion may be at the lower end of the reinforcing part and may abut and support the base of the body portion during lifting.

[0067] The reinforcing part may comprise elongate members extending substantially the height of the container and bracing members between the elongate members. The bracing members may be cross-bracing members that act as cross braces.

[0068] The reinforcing part may comprise robot engagement structure at its upper end for engaging with a lifting device of a robot container-handling vehicle for lifting the container. The rim may comprise robot engaging structure for engaging with a lifting device of a robot container-handling vehicle for lifting the container.

[0069] The reinforcing part may be formed of plastic. The reinforcing part may be formed of a composite material. The reinforcing part may be fibre-matrix composite. For example, it may be formed of glass reinforced plastic (GRP). The reinforcing part may be formed of metal. It may be extruded; it may be cast; it may be milled.

[0070] The container may comprise a plurality of the reinforcing parts.

[0071] The container may comprise a flange part extending around the base of the body part and arranged to substantially close the open top of a container on which the container is stacked. By substantially closing that lower container in this way, it is less likely that a fire will start in that lower container or will spread from it if a fire has started. It is also less likely that a fire will spread into that lower container from outside it. Closing the lower container also helps keep water from entering the lower container in the event that a sprinkler system is triggered.

[0072] The flange part may be annular - that is, it may have a cut-out section defining the flange therearound. This helps save weight. The flange part may be coupled to the base of the body part. The base of the body part and the flange may, together, substantially close the otherwise open top of a container on which the container is stacked.

[0073] The flange may comprise the lower interface structure. The flange may at least partly fix the reinforcing part to the body part. The flange may surround the body-part-engaging-portion of the reinforcing part to fix that portion to the body part.

[0074] The reinforcing part may comprise locating structure to locate the reinforcing part relative to the body part. The locating structure may comprise one of male and female locating structure being provided at an upper end of the reinforcing part and the other of the male and female locating structure being provided in the rim of the body part. The male locating structure may project through apertures in a rim of the body part to at least partly fix the reinforcing part thereto.Penultimate comments

[0075] It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other implementations will be apparent to those of skill in the art upon reading and understanding the above description. Although the present disclosure has been described with reference to specific example implementations, it will be recognized that the disclosure is not limited to the implementations described, but can be practiced with modification and alteration within the spirit and scope of the appended claims. Accordingly, the specification and drawings are to be regarded in an illustrative sense rather than a restrictive sense. The scope of the disclosure should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Examples

Embodiment Construction

[0009]In overview, the disclosure relates to a modified container for use with an automated storage and retrieval system of the kind described hereinabove. The modified container is to be used in generally the same way as the unmodified container described above; that is, the modified container is for holding goods stored within the grid and is arranged so that several of the modified containers can be arranged in a stack. Also as described above, the modified container can be retrieved and rearranged by the robotic container-handling vehicles.

[0010]The modified container addresses drawbacks of existing containers by modifications that allow it to be arranged in stacks higher than 6m. This is done without risking the structural failure and collapse of the container at the bottom of the stack, without compromising the effectiveness of existing sprinkler systems in controlling and putting out a fire affecting the grid, without increasing the weight of the container so that it cannot b...

TECHNICAL FIELD

[0001] The disclosure relates to a storage container. More particularly, it relates to a storage container for use in an automated storage and retrieval system.BACKGROUND

[0002] Traditional storage solutions usually involve the arrangement of goods on rows of shelves within a warehouse. The shelf location for each item is recorded in an inventory, and goods are retrieved from the shelves by a stock picker. The shelves are restocked and the inventory updated, as needed, as goods enter and leave the warehouse.

[0003] Warehouse workers may be assisted by robotic pickers and by automated inventory management systems. Automated transit systems may also be implemented in traditional warehouse set-ups to move goods from their inventory location to a picking and / or packing station.

[0004] An alternative to a traditional warehouse set-up is an automated storage and retrieval system in which robots retrieve items from their logged location within the warehouse and deliver the items to a packing station or port. Such systems can reduce or eliminate the space needed to pass between rows of shelves to access stock, thereby removing the need for broad aisles within the warehouse. One example of such a system involves placing goods in plastic bins or containers that are configured to be stacked on top of each other, and with stacks of the plastic containers arranged side by side, within a three-dimensional grid. A rail system is arranged on top of the grid, along which robotic container-handling vehicles configured to lift containers from the grid can travel. The container-handling vehicles are configured to transport containers from the grid and to deliver them to ports or stations at the periphery of the grid so that the goods within the container can be picked and packed.

[0005] In order to maximise the useful storage volume of the automated storage and retrieval system, it is desirable to increase the size of the three dimensional grid to fill as much of the warehouse as possible. This includes increasing the height of the grid to use as much vertical space as possible. However, while the existing plastic containers are strong enough and light enough to allow stacks up to 6m tall, at stack heights above that the load bearing down on the bottom container in the stack may be large enough to crush that container. Also, in the event of a fire, existing sprinkler systems may lose effectiveness with stacks of existing containers higher than 6m. For these reasons, 6m is currently a maximum height for stacks of containers in the automatic storage and retrieval system.

[0006] An alternative approach might be to use metal containers, which are more resistant to fire. This would allow existing sprinkler systems to maintain their effectiveness with stacks of containers over 6m. However, a metal container that can withstand the loading of a stack of containers on top of it higher than 6m would be prohibitively expensive and too heavy for handling by existing container-handling vehicles and other equipment of the system.

[0007] One or more aspects of the invention of the present application are set out in the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The disclosure will now be described in more detail in connection with a number of exemplary embodiments shown in the accompanying drawings, in which: Fig. 1 shows a perspective view of a storage system comprising a grid and a plurality of robotic container-handling vehicles configured to retrieve and / or rearrange goods stored within the grid; Fig. 2 shows a top view of the system of Fig. 1; Fig. 3A shows a side view of a first robotic container-handling vehicle suitable for use in the system of Fig. 1; Fig. 3B shows a side view of a second robotic container-handling vehicle suitable for use in the system of Fig. 1; Fig. 3C is a perspective side view of the robot of Fig. 3B; Fig. 3D is an underneath perspective view of the robot of Fig. 3B and Fig. 3C; Fig. 4 shows an existing computing device for implementing the operations described herein; Fig. 5 is a perspective view of a modified container that is for retrieving and rearranging by the robotic container handling vehicles, the modified container modified to embody this invention; Fig. 6 shows an exploded view of the modified container of Fig. 5, showing component parts of the modified container; Fig. 7 is a detailed view of a reinforcing part of the modified container; Fig. 8 is a perspective view of three of the modified containers in a stacked arrangement; and Fig. 9 is a perspective sectional view of two of the modified containers in a stacked arrangement. DETAILED DESCRIPTION

[0009] In overview, the disclosure relates to a modified container for use with an automated storage and retrieval system of the kind described hereinabove. The modified container is to be used in generally the same way as the unmodified container described above; that is, the modified container is for holding goods stored within the grid and is arranged so that several of the modified containers can be arranged in a stack. Also as described above, the modified container can be retrieved and rearranged by the robotic container-handling vehicles.

[0010] The modified container addresses drawbacks of existing containers by modifications that allow it to be arranged in stacks higher than 6m. This is done without risking the structural failure and collapse of the container at the bottom of the stack, without compromising the effectiveness of existing sprinkler systems in controlling and putting out a fire affecting the grid, without increasing the weight of the container so that it cannot be handled by existing robotic container-handling vehicles, and without prohibitively increasing the cost of the container.

[0011] In this embodiment, this performance by the modified container is achieved by: a body part of non-flammable material, such as thin sheet metal, that contains the goods to be held, but does not provide the structural strength of the container to support other containers on top of it; and a reinforcing part that reinforces the body part and does provide the structural strength to support other, like, modified containers in a stack on top of the modified container. By providing the body part of non-flammable material, such as metal, a fire within the modified container is less likely to spread from the container elsewhere, and a fire outside the modified container is less likely to spread inside the container. Thus, a stack higher than 6m can be achieved without compromising the effectiveness of existing sprinkler systems. As the body part does not provide the structural strength for stacking, it can be made of thin material, such as thin, sheet metal. Thus, the weight of the body part is minimised, which aids handling and also helps increase stack height. The reinforcing part provides the needed structural strength for stacking that the body part on its own lacks. As the goods are protected within the modified container by the body part, there is greater material choice over the reinforcing part and so a strong, light material can be chosen that does not necessarily need to be non-flammable (although it could be). Thus, the reinforcing part can sufficiently strengthen the modified container to allow stacks over 6m without increasing weight to a level that would hinder handling or cause the lowest container in the stack to fail. Plastic is used in this embodiment. In this embodiment a flange part is also provided and fixed to the bottom of the body part to help close the open top of the modified container below it in the stack to further guard against first spreading to or from the inside of the container and also to protect goods within the container from becoming wet and be being spoiled should a sprinkler system be set off.

[0012] A general description of the automated storage and retrieval system will now be given, with reference to Fig. 1 to Fig 4, by way of background to understanding the invention. The modified container will then be described with reference to Fig. 5 to Fig. 9.Automated storage and retrieval system overview

[0013] Referring to the embodiment shown in Fig. 1, a grid 100 comprises a frame formed by a plurality of generally rectilinear, adjacent vertical columns 102 formed between vertical frame members 104 and extending in the X and Y directions 108, 110. The grid elements may be fabricated of any appropriate material; for example, the frame members may be formed of extruded aluminium. Storage containers or bins 112 are stacked on top of each other, preferably in a self-supporting manner, in the Z direction 114 in the columns 102, forming a storage volume of storage cells for respective bins 112 extending in the X, Y and Z directions 108, 110, 114.

[0014] A rail system or network 116 is formed on top of the grid 100 and comprises pairs of vehicle rails or tracks 118a, 118b and 120a, 120b, respectively extending in the X and Y directions 108, 110. Robotic container-handling vehicles, or robots, 122, which can be of a range of size, shape and function, are provided and configured to run on the rails 118, 120 and to transport bins 112 in both the X and Y directions 108, 110. The robots 122 are additionally configured to lift and lower bins 112 from / into the columns 102 in the Z direction 114, the bins 112 optionally being guided by the vertical frame members 104. The robots 122 access the bins 112 via access openings 124 above the columns 102 and formed between the rails 118, 120.

[0015] Some columns 102 may be used for alternative purposes than bin storage. For example, port columns 126, 128 comprise port or access columns allowing transfer of a bin 112 in and / or out of the grid 100. Port columns 126, 128 provide a vertical channel for lifting of a bin 112 from, or lowering of a bin 112 to, a port or ports 130, 132. The ports 130, 132 are shown in Fig. 1 at the lowest level of the grid, however ports can be located at any vertical position along the column. The respective port columns 126, 128 can be assigned for removing ('drop-off) and / or returning or delivering ('pick-up') bins 112 from / to the grid 100. The ports 130, 132 are therefore configured to allow bins 112 to be removed and reintroduced (horizontally) into the associated port column. As such, a port 130, 132 can comprise a conveyor (not shown in Fig. 1) onto which a bin 112 may be lowered and transported horizontally out of the port column. The port columns 126, 128 include an opening or access point through which bins 112 can enter and leave the column.

[0016] Bins 112 can be transported along the top of the grid 100 to and / or from a port column 126, 128 by robots 122, and from a port 130, 132 to a location outside the grid 100, which may be an access station (not shown) for processing of the bin 112 or its contents, such as a picking station for adding content to, or removing content from, the bin 112. In alternative examples (not shown), the bin 112 may be transported to a port of another grid on the same or another level, or to an external facility. Transport of bins 112 to and from ports 130, 132 may be by any appropriate means (not shown) including conveyors, transport vehicles, lifts or robots.

[0017] Referring to the embodiment shown in Fig. 2, the X-Y configuration 200 of the rail system 116 can be seen in more detail, together with robots 202, 204 of different types. The rail system includes rails 206 defining between them vertical column access openings 124 for access to bins 112. The rails 206 can be any appropriate type for permitting travel of the robots 202, 204 in the X and Y directions 108, 110 thereon, including (not shown) groove-type rails for receiving vehicle wheels, or protrusion-type rails for engaging wheel recesses. Each rail 206 may comprise a single track or multiple parallel tracks in each of the X and Y directions 108, 110.

[0018] A first, 'cantilever' type of robot 202 is shown in more detail in Fig. 3A and includes a body 300, a set of wheels 302 and a lifting device 304. The body 300 contains operational equipment (not shown) for the robot 202 including drive, power and control systems. The wheels 302 permit movement of the robot 202 in one of the X and Y directions, an additional set of wheels (not visible in this view) permitting movement in the other of the X and Y directions, in both cases along the respective rails or tracks 206. One or both sets of wheels can be raised or lowered to permit selective engagement of the rails for movement in the desired direction. The lifting device 304 includes a cantilever element 306 extending in the X-Y plane from the top of the body 300, and a gripping device 308, which is raisable and lowerable from the cantilever element 306. The gripping device 308 is configured to grip or engage a bin 112; for example, by gripping a part of the bin 112, or by passively or actively engaging a suitably configured part of the bin 112.

[0019] A second, 'internal cavity' type of robot 204 is shown in more detail in Fig. 3B and includes, as an alternative to the cantilevered lifting system, an internal cavity 310 within the body 300 and in which the lifting device 312 including a gripping device (not shown) is located. In this case, the body 300 includes the robot's operational equipment and a storage space for one or more bins 112, for use, for example, while transporting the bin 112.

[0020] Fig. 3C shows a perspective side view of the robot of Fig. 3B in which the first set of wheels 302 from Fig. 3B are visible. The additional set of wheels referenced above but not shown in Fig. 3B are shown as wheels 303 in Fig. 3C. The additional set of wheels 303 is arranged perpendicular to the first set of wheels 302, to allow rolling of the robot 204 in the X and Y directions on the first and second set of wheels 302, 303 respectively. The first and second set of wheels 302, 303 shown in Fig. 3C may be configured to be independently lowered into engagement with the rails (and conversely raised out of engagement with the rails) to allow the robot 202 to move in the X and Y direction across the arrangement of rails shown in Fig. 2. Although the perspective view shown in Fig. 3C is of the robot 204 of Fig. 3B, it will be appreciated that a similar perpendicular wheel arrangement may be applied to the robot 202 of Fig. 3A.

[0021] Fig. 3D shows a perspective view of the internal cavity type of robot 204 shown in Fig. 3C. The gripping device 350 of the robot 204 can be seen in Fig. 3D and will now be explained. With continued reference to Fig. 3D, the gripping device 350 includes a platform 352 extending in the X and Y plane and that is rectangular when viewed in the Z direction. The gripping device 350 also includes a plurality of engagement fingers in the form of four location fingers 354 and four pairs of latching fingers 356.

[0022] Each of the location fingers 354 is a downwardly projecting spike, projecting from the platform 352 in the Z direction and mounted at a respective corner of the platform 352. The location fingers 354 are sized, shaped and positioned to slide over and locate the corners of a bin 112 when the gripping device 350 is lowered to a bin 112 to engage it for lifting. When so engaged, an outside surface of each bin corner abuts a respective one of the location fingers 354, thereby being located relative thereto in the X-Y plane.

[0023] Each pair of latching fingers 356 has a downwardly projecting portion projecting in the Z direction with a sideways projecting portion on the end of each finger of the pair. The sideways projecting portions of each pair project away from each other in the X-Y plane. The latching fingers 356 are sized, shaped and positioned to be inserted in an aperture formed in structure of the bin 112 when the gripping device 350 is lowered to the bin 112 to engage it for lifting. The latching fingers are also arranged to be operated to pivot the latching fingers 356 of each pair apart so that the sideways projecting portion of each pair moves apart to latch around cooperating structure (not shown) of the bin 112, thereby engaging the bin 112 for lifting with the gripping device 350 by operating the lifting device 312.

[0024] Fig. 3D shows elongate flexible members 360 of the lifting device 312. The elongate flexible members 360 are four cables 360. A respective cable 360 is anchored to the platform 352 of the gripping device 350 towards each corner of the platform 352. The other end of each cable 360 is connected to structure (not shown) of the lifting device 312 for winding in and winding out the cables 360, thereby raising and lowering the gripping device 350 and any bin 112 with which it is engaged.Control and monitoring system

[0025] Control and monitoring of the automated storage and retrieval system, including monitoring and storing bin position and controlling bin delivery, retrieval and transport and robot routing and collision avoidance, is performed by a control system shown in Fig. 4 in communication with the robots and / or other controllable system components. Control can be performed locally or remotely and may be implemented by a processing system, for example in the form of a computing device. Accordingly, the methods described herein may form all or part of a computer-implemented method, or a system configured to perform the methods described herein.

[0026] With reference to Fig. 4, a processing system 400 suitable for carrying out the methods described herein will now be described. Fig. 4 shows a block diagram of one implementation of a processing system 400 in the form of a computing device within which a set of instructions for causing the computing device to perform any one or more of the methods described herein may be executed. In some implementations, the computing device may be connected (e.g., networked) to other machines in a Local Area Network (LAN), an intranet, an extranet, or the Internet. The computing device may operate in the capacity of a server or a client machine in a client-server network environment, or as a peer machine in a peer-to-peer (or distributed) network environment. The computing device may be a personal computer (PC), a tablet computer, a set-top box (STB), a Personal Digital Assistant (PDA), a cellular telephone, a web appliance, a server, a network router, switch or bridge, or any machine capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that machine. Further, while only a single computing device is illustrated, the term `computing device' shall also be taken to include any collection of machines (e.g., computers) that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methods described herein.

[0027] The example processing system 400 includes a processor 402, a main memory 404 (e.g., read-only memory (ROM), flash memory, dynamic random-access memory (DRAM) such as synchronous DRAM (SDRAM) or Rambus DRAM (RDRAM), etc.), a static memory 406 (e.g., flash memory, static random-access memory (SRAM), etc.), and a secondary memory (e.g., a data storage device 418), which communicate with each other via a bus 430.

[0028] Processor 402 represents one or more general-purpose processors such as a microprocessor, central processing unit, or the like. More particularly, the processor 402 may be a complex instruction set computing (CISC) microprocessor, reduced instruction set computing (RISC) microprocessor, very long instruction word (VLIW) microprocessor, processor implementing other instruction sets, or processors implementing a combination of instruction sets. Processor 402 may also be one or more special-purpose processors such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), network processor, or the like. Processor 402 is configured to execute the processing logic (instructions 422) for performing the operations and steps described herein.

[0029] The processing system 400 may further include a network interface device 408. The processing system 400 also may include any of a video display unit 410 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)), an alphanumeric input device 412 (e.g., a keyboard or touchscreen), a cursor control device 414 (e.g., a mouse or touchscreen), and an audio device 416 (e.g., a speaker).

[0030] It will be apparent that some features of the processing system 400 shown in Fig. 4 may be absent. For example, the processing system 400 may have no need for display device 410 (or any associated adapters). This may be the case, for example, for particular server-side computer apparatuses which are used only for their processing capabilities and do not need to display information to users. Similarly, user input device 412 may not be required. In its simplest form, processing system 400 comprises processor 402 and main memory 404.

[0031] The data storage device 418 may include one or more machine-readable storage media (or more specifically one or more non-transitory computer-readable storage media) 428 on which is stored one or more sets of instructions 422 embodying any one or more of the methods or functions described herein. The instructions 422 may also reside, completely or at least partially, within the main memory 404 and / or within the processor 402 during execution thereof by the processing system 400, the main memory 404 and the processor 402 also constituting computer-readable storage media 428.

[0032] The various methods described herein may be implemented by a computer program. The computer program may include computer code arranged to instruct a computer to perform the functions of one or more of the various methods described herein. The computer program and / or the code for performing such methods may be provided to an apparatus, such as a computer, on one or more computer-readable media or, more generally, a computer program product. The computer-readable media may be transitory or non-transitory. The one or more computer-readable media could be, for example, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, or a propagation medium for data transmission, for example for downloading the code over the Internet. Alternatively, the one or more computer-readable media could take the form of one or more physical computer-readable media such as semiconductor or solid-state memory, magnetic tape, a removable computer diskette, a random-access memory (RAM), a read-only memory (ROM), a rigid magnetic disc, or an optical disk, such as a CD-ROM, CD-R / W or DVD.

[0033] The computer program is executable by the processor 402 to perform functions of the systems and methods described herein.

[0034] In an implementation, the modules, components, and other features described herein can be implemented as discrete components or integrated in the functionality of hardware components such as ASICS, FPGAs, DSPs, or similar devices.

[0035] A 'hardware component' is a tangible (e.g., non-transitory) physical component (e.g., a set of one or more processors) capable of performing certain operations and may be configured or arranged in a certain physical manner. A hardware component may include dedicated circuitry or logic that is permanently configured to perform certain operations. A hardware component may be or include a special-purpose processor, such as a field programmable gate array (FPGA) or an ASIC. A hardware component may also include programmable logic or circuitry that is temporarily configured by software to perform certain operations.

[0036] Accordingly, the phrase 'hardware component' should be understood to encompass a tangible entity that may be physically constructed, permanently configured (e.g., hardwired), or temporarily configured (e.g., programmed) to operate in a certain manner or to perform certain operations described herein.

[0037] In addition, the modules and components can be implemented as firmware or functional circuitry within hardware devices. Further, the modules and components can be implemented in any combination of hardware devices and software components, or only in software (e.g., code stored or otherwise embodied in a machine-readable medium or in a transmission medium).Operation of the automated storage and retrieval system

[0038] In operation, each bin 112 is given a unique identifier, which maybe marked on the bin 112 using a computer-readable identifier (e.g., a barcode, quick-response code or radio-frequency identification tag) to ease identification of the bin 112. A database of the processing system 400 stores, in association with the unique identifier, the position and, optionally, content of each bin 112. When a bin 112 is moved (e.g., when it is retrieved from the grid 100), the database is updated to record its change in position.

[0039] When it is desired to retrieve a bin 112 from the grid 100, under control of the processing system 400, a robot 202, 204 is routed via the rail system 116 to the vertical column 102 including the storage cell where, according to the database, the bin 112 is positioned, and the lifting device 304, 312 is positioned (according to robot type) over the corresponding access opening 124, either adjacent or below the robot 202, 204. The robot 202, 204 lowers the gripping device 308 which engages, grips and lifts the bin 112 to the robot 202, 204. The robot 202, 204 then transports the bin 112, for example, to the drop-off port column 126, 128 for delivery to the port 130, 132 and subsequent processing external to the grid 100. In the event that the target or designated bin 112 is below other bins in the stack then the robot 202, 204 or multiple robots, which may be dedicated to the task, are controlled in a 'digging' operation to sequentially lift and reposition, temporarily or permanently, bins above the target bin 112 in order for it to be retrieved. It will be appreciated that other operations in relation to the bin 112 can be carried out in a similar manner. For example, a bin 112 can be delivered for storage in the grid 100 at the port 130, 132 of the pick-up port column 126, 128, gripped and lifted by a robot 202, 204 and delivered to the desired storage cell, bins above the desired position being repositioned if necessary as discussed above.Description of specific improvements

[0040] As can be seen in Fig. 5, the modified container, which will also be referred to as the modified bin 502 is made up of a body part 504, four reinforcing parts 506 (only two of which are visible in Fig. 5) and a flange part 508.

[0041] The body part 504, when the bin 502 is positioned as it would be in use for containing goods, has four generally vertical walls 510 at right angles and a base 512 (visible in Fig. 8). In other words, the walls extend in the z direction and the base lies in the x-y plane. The walls 510 and base 512 are integrally formed and so are joined to each other at their edges where they meet so as not to have holes or gaps between or in them (except as will be described below). Thus, the body part 504 is an open-topped receptacle for goods that is sealed, except for that open top. The body part 504 further includes an outwardly-projecting lip 505 around its upper edge.

[0042] The four reinforcing parts 506 are fixed to the outside of the bin, spaced apart and, when the bin is positioned as it would be in use for containing goods, extend from the top of the bin 502 to its base.

[0043] The flange part 508 is fixed to the bottom of the bin 502 and extends out from the bin, in a generally horizontal direction, all around the bottom of the bin 502.

[0044] More details of each of these components will now be described with reference to Fig. 6, which shows the body part 504, the reinforcing parts 506 and the flange part 508 spaced apart from each other before assembly.

[0045] With continued reference to Fig. 6, in this embodiment the body part 504 is formed of 0.5mm thick sheet steel. It is envisaged that the body part 504 is formed from this material using existing techniques. The body part 504 is formed to have reinforcing features in the form of three box-profile ribs 514 in each wall 510, extending the height of each wall 510.

[0046] The reinforcing parts 506 are each the same as each other. One 506 will now be described with reference to Fig. 7, it being understood that this description is representative of all four reinforcing parts 506. The reinforcing part 506 is formed of plastic. It serves as a column to support the load of others of the modified bin 502 stacked above it and to transfer that load to others of the modified bin stacked below it, or to the base of the grid if the modified bin 503 is the lowest bin of the stack. The reinforcing part 506 is generally a u-section column with additional reinforcement. The u-section is formed of (1) a web 516 that lies face-to-face against one of the walls 510 of the body part 504 when the reinforcing part 506 is fixed thereto, and (2) a flange 518 at each edge of the web 516 and perpendicular thereto so that they project from the wall 510 of the body part 504 to which the reinforcing part 508 is fixed. The additional reinforcement is provided by a series of cross braces 520 between the flanges. The reinforcing part 506 is formed as a single piece and so the web 516, flanges 518 and cross braces 520 are all integrally formed and connected to each other.

[0047] The reinforcing part 506 further includes a foot 522 at the bottom of each flange 518. When the reinforcing part 506 is fixed to the body part 504, each foot 522 projects towards the body part 504 and is shaped and configured to extend beneath the base 512 so that the top of each foot 522 abuts the base 512. As will be seen, this supports and lifts the body part 504 when the container 502 is engaged and lifted by a robot, such as those 202, 204 described above with reference to Figs. 1-4.

[0048] With continued reference to Fig. 7, the reinforcing part 506 further includes two shoulders 524, each extending in a horizontal plane from the top of the web 516 a the top of a respective one of the flanges 518. Each shoulder 524 has a spigot 526 that projects upwardly from it.

[0049] With reference to Fig. 6, the flange part 508 is a generally rectangular frame. It is also formed of 0.5mm thick sheet steel. The flange part 508 has an inner portion 528 and an outer portion 530. The inner portion 528 is shaped and configured for fitting face-to-face against the base 512 of the body part 504 so that it extends around the permitter of that base 512. The outer portion 530 extends outwards from the inner portion, and so outwardly from the base 512 of the body part 504 when fitted to it, in a horizontal plane. The flange part 508 includes a transition between the inner portion 528 and the outer portion 530 so that the two portions are vertically displaced from each other, the outer portion being lower.

[0050] With continued reference to Fig. 6, the modified bin 502 is assembled by fixing firstly all four of the reinforcing parts 506 to the body part 504, and then fixing the flange part 508 to the body part 504. How this is done will now be described.

[0051] Each reinforcing part 506 is fitted to the body part 504 by inserting the two spigots 526 of the reinforcing part through cooperating holes in the rim 505 of the body part 504. This locates the top of each reinforcing part 506 relative to the body part 504. The bottom of each reinforcing part 506 is then moved towards the body part 504 so that the web 516 of each lies against one of the walls 510 of the body part 504, and so that the feet 522 of each reinforcing part 506 extend underneath and abut the base 512 of the body part 504. Thus the feet 522 act as a body-part-engaging portion of the reinforcing part 506.

[0052] The flange 508 is then fitted against the base 512 of the body part 504. Cut outs 532 in the inner portion 528 and in the transition of the flange 508 accommodate the feet 522 of each reinforcing part 506 and locate the bottom of each reinforcing part 506 relative to the flange 508 and relative to the body part 504. The flange 508 is spot welded to the base 512 of the body part 504 to secure all the components together. Thus, the modified bin 502 is assembled. It should also be noted that the flange 508 includes a pair of semi-circular cut-outs 534 in the outer edge of the outer portion 530 of the flange 508. The purpose of these will later be made clear when use of the modified bin 502 is described.

[0053] Use of the modified bin 502 will now be described with reference to Fig. 8 and Fig. 9. Fig. 8 shows three of the modified bins 503 stacked on top of each other. When stacked, the various components and features of each bin 503 cooperate with those of the bin 502 above and the bin 502 below.

[0054] Firstly, as can be seen in Fig. 8, the reinforcing parts 506 are arranged above each other to form load-bearing columns to take the weight of the bins 502 in the stack and transmit this to the base of the grid. More particularly, the shoulders 524 of each reinforcing part 506 abut up against the underside of the rim 505 of the body part 504, which in turn abuts up against the outer portion 530 of the flange 508 of the bin 502 above. (Thus, for each of the bins 502, the rim 505 acts as upper interface structure and the flange 508 acts as lower interface structure.) At the other end of the reinforcing parts 506, the bottom of the feet 522 abut down against the upper side of the outer portion 530 of the flange 508 of the bin 502 to which they are fitted. When stacked, the spigots 526 of the lower bin 502 fit inside the semi-circular cut-outs 534 in the outer edge of the flange 508 of the upper bin 502.

[0055] Also, as can be seen in Fig. 8, the flange 508 closes an annular gap that would otherwise exist between upper and lower bins 502. This can be seen more clearly in the sectional view of Fig. 9. Here it can be seen that the inner portion 528 of the flange 508 is fixed face-to-face to the underside of the base 512 of the upper bin 502 and creates a seal with that base 512. It can also be seen that the outer portion 530 of the flange 508 lies on top of and in face-to-face contact with the rim 505 of the lower bin 502, creating a seal with that bin 502. Thus, each bin 502 is closed when beneath another 502 in a stack. Fig. 9 also shows how the transition between the inner portion 528 and outer portion 528 of the flange 508 vertically displaces these two portions to accommodate the feet 522 of the reinforcing parts 506.

[0056] None of the figures shows the modified bin 502 being engaged by a robot 202, 204 for lifting. It is envisaged that the modified bin 502 be engaged and lifted in the same way as existing bins, such as those 112 described above with reference to and as shown in Figs. 1 to 4. Specifically, the upper portion of each of the reinforcing parts 506 of the modified bin 502 is shaped and configured to be engaged by the latching fingers 356 latching underneath the shoulders 524 so as abut an underside of those shoulders. Thus, the latching fingers 356 can be raised up by the robot 202, 204 to which they are attached to lift the reinforcing parts 506 and hence the modified bin 502.Additional disclosure

[0057] In a first aspect of this invention, there is provided a storage container for use in an automated storage and retrieval system, in which system a plurality of the containers can be stacked, one on top of another, the container comprising: a body part formed of a non-flammable material, the body part arranged to hold goods for storage and retrieval, at least one reinforcing part coupled to the body part and arranged to withstand the compressive load of containers stacked on top of the container and to transmit this load to structure below the container.

[0058] The plurality of the containers may each be substantially the same as the container. For example, the plurality of containers may be made to the same design, the same specification and in the same way as the container. There may be some insubstantial differences between ones of the containers due to normal manufacturing variation.

[0059] The structure below the container may be structure of another container on which the container is stacked. The structure below the container may be a base of the system on which the lowest container in a stack rests.

[0060] The body part may comprise a base and sides that form the base and sides of the container. The base and sides of the body part may form a substantially continuous enclosure. By avoiding holes or other gaps in the base and sides, this helps to avoid a fire in the container spreading outside the container; it also helps avoid a fire outside the container spreading inside the container. It also guards against water from a sprinkler system entering the container and spoiling goods in the container in the event that a fire triggers operation of the sprinkler system.

[0061] The body part may comprise an open top that is also an open top of the container. The open top of the container may be at least partly closed by the base of another of the containers when stacked on top of the container.

[0062] The body part may be arranged not to transmit the load of containers stacked on top of the container to structure below the container. The body part may fail if, without the reinforcing part coupled to it, other containers with goods inside them are stacked on top of the container.

[0063] The body part may be formed of sheet material. It may be formed of sheet metal, for example steel. It may be formed of thin sheet metal. The sheet material and / or the thickness of the body part may be less then 1mm thick. It may be between 0.25mm and 0.75mm thick. It maybe 0.5mm thick.

[0064] The reinforcing part may be of a flammable material. The reinforcing part may be outside the body part when coupled thereto. Should the reinforcing part catch fire, it is therefore less likely to set fire to goods within the body part and can more easily be accessed and doused by a sprinkler system. The reinforcing part may be inside the body part when coupled thereto.

[0065] The reinforcing part may be coupled to the body part so as to abut interface structure of the container. The interface structure may be structure of the body part. The interface structure of the container may be structure arranged to abut the interface structure of another container. The container may have upper interface structure and lower interface structure. The upper interface structure may be a lip projecting from the upper periphery of the body part, for example around the open top. The lower interface structure may be the flange part. The reinforcing part may extend between the two interface structures and abut each. When stacked, the upper interface structure of the container may abut the lower interface structure of another container stacked on top of the container, and the lower interface structure of the container may abut the upper interface structure of a further container stacked below the container. In this way, the reinforcing part acts as a compressive support. In other words, the reinforcing part acts as a column.

[0066] As well as withstanding the compressive load of containers stacked on top of the container, the at least one reinforcing part may also be coupled to the body part to lift the body part and arranged to withstand the tensile load of lifting the body part. The reinforcing part may comprise a body-part-engaging portion to engage and support the body part during lifting. The body-part-engaging portion may be at the lower end of the reinforcing part and may abut and support the base of the body portion during lifting.

[0067] The reinforcing part may comprise elongate members extending substantially the height of the container and bracing members between the elongate members. The bracing members may be cross-bracing members that act as cross braces.

[0068] The reinforcing part may comprise robot engagement structure at its upper end for engaging with a lifting device of a robot container-handling vehicle for lifting the container. The rim may comprise robot engaging structure for engaging with a lifting device of a robot container-handling vehicle for lifting the container.

[0069] The reinforcing part may be formed of plastic. The reinforcing part may be formed of a composite material. The reinforcing part may be fibre-matrix composite. For example, it may be formed of glass reinforced plastic (GRP). The reinforcing part may be formed of metal. It may be extruded; it may be cast; it may be milled.

[0070] The container may comprise a plurality of the reinforcing parts.

[0071] The container may comprise a flange part extending around the base of the body part and arranged to substantially close the open top of a container on which the container is stacked. By substantially closing that lower container in this way, it is less likely that a fire will start in that lower container or will spread from it if a fire has started. It is also less likely that a fire will spread into that lower container from outside it. Closing the lower container also helps keep water from entering the lower container in the event that a sprinkler system is triggered.

[0072] The flange part may be annular - that is, it may have a cut-out section defining the flange therearound. This helps save weight. The flange part may be coupled to the base of the body part. The base of the body part and the flange may, together, substantially close the otherwise open top of a container on which the container is stacked.

[0073] The flange may comprise the lower interface structure. The flange may at least partly fix the reinforcing part to the body part. The flange may surround the body-part-engaging-portion of the reinforcing part to fix that portion to the body part.

[0074] The reinforcing part may comprise locating structure to locate the reinforcing part relative to the body part. The locating structure may comprise one of male and female locating structure being provided at an upper end of the reinforcing part and the other of the male and female locating structure being provided in the rim of the body part. The male locating structure may project through apertures in a rim of the body part to at least partly fix the reinforcing part thereto.Penultimate comments

[0075] It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other implementations will be apparent to those of skill in the art upon reading and understanding the above description. Although the present disclosure has been described with reference to specific example implementations, it will be recognized that the disclosure is not limited to the implementations described, but can be practiced with modification and alteration within the spirit and scope of the appended claims. Accordingly, the specification and drawings are to be regarded in an illustrative sense rather than a restrictive sense. The scope of the disclosure should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Examples

Embodiment Construction

[0009]In overview, the disclosure relates to a modified container for use with an automated storage and retrieval system of the kind described hereinabove. The modified container is to be used in generally the same way as the unmodified container described above; that is, the modified container is for holding goods stored within the grid and is arranged so that several of the modified containers can be arranged in a stack. Also as described above, the modified container can be retrieved and rearranged by the robotic container-handling vehicles.

[0010]The modified container addresses drawbacks of existing containers by modifications that allow it to be arranged in stacks higher than 6m. This is done without risking the structural failure and collapse of the container at the bottom of the stack, without compromising the effectiveness of existing sprinkler systems in controlling and putting out a fire affecting the grid, without increasing the weight of the container so that it cannot b...

Claims

1. A storage container for use in an automated storage and retrieval system, in which system a plurality of the containers can be stacked, one on top of another, the container comprising: a body part formed of a non-flammable material, the body part arranged to hold goods for storage and retrieval, at least one reinforcing part coupled to the body part and arranged to withstand the compressive load of containers stacked on top of the container and to transmit this load to structure below the container.

2. A storage container according to claim 1, wherein the body part is formed of sheet material, for example sheet metal.

3. A storage container according to claim 1 or claim 2, wherein the reinforcing part is outside the body part when coupled thereto.

4. A storage container according to any preceding claim, wherein the reinforcing part is of a flammable material and / or the reinforcing part is formed of plastic and / or the reinforcing part is formed of a composite material.

5. A storage container according to any preceding claim, wherein the reinforcing part is coupled to the body part so as to abut interface structure of the container, the interface structure arranged to abut the interface structure of another, like, container.

6. A storage container according to any preceding claim, wherein the container has upper interface structure and lower interface structure, the reinforcing part extending between the upper and lower interface structure and abutting each.

7. A storage container according to any preceding claim, wherein the reinforcing part comprises a body-part-engaging portion to engage and support the body part during lifting of the container.

8. A storage container according to any preceding claim, wherein the body-part-engaging portion is at the lower end of the reinforcing part and abuts and supports the base of the body portion during lifting.

9. A storage container according to any preceding claim, wherein the reinforcing part comprises elongate members extending substantially the height of the container and bracing members between the elongate members.

10. A storage container according to any preceding claim, wherein the reinforcing part comprises robot engagement structure at its upper end for engaging with a lifting device of a robot container-handling vehicle for lifting the container.

11. A storage container according to any preceding claim, wherein the container comprises a plurality of the reinforcing parts.

12. A storage container according to any preceding claim, wherein the container comprises a flange part extending around the base of the body part and arranged to substantially close the open top of a container on which the container is stacked, and optionally wherein the flange part is annular.

13. A storage container according to any preceding claim, wherein the flange at least partly fixes the reinforcing part to the body part, and optionally where in the flange surrounds the body-part-engaging-portion of the reinforcing part to fix that portion to the body part.

14. A storage container according to any preceding claim, wherein the reinforcing part comprises locating structure to locate the reinforcing part relative to the body part15. The locating structure may comprise one of male and female locating structure being provided at an upper end of the reinforcing part and the other of the male and female locating structure being provided in the rim of the body part.

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