Top level of frame structure

Abstract

To provide a system and a method capable of improving reliability and reducing the cost of the whole processing system of a large container by using one or a plurality of robot service devices.SOLUTION: A robot service device is described for use of a grid in a robot take-out system. The robot service device is capable of being driven to any location on the grid in order to perform maintenance operations or cleaning. Additionally, the robot service device can be used to assist a plurality of robot load handling devices capable of being operated in the take-out system. The robot service device may have a releasable docking mechanism to enable it to dock and latch to the robot load handling devices. The robot service device may also have cleaning means and camera means to enable the grid and the robot load handling devices to be monitored.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to apparatus and methods for robotic pick-up systems, particularly but not exclusively to a robotic servicing apparatus for use in a robotic pick-up system and a method for improving the reliability of such a system. This application claims the benefit of priority from UK patent application no. GB ​​1404870.6, filed on 18 March 2014, which is incorporated herein by reference. [Background technology]

[0002] Some commercial and industrial operations require a system that allows for the storage and retrieval of many different goods. One known type of system for the storage and retrieval of goods in multiple production lines involves arranging storage bins or containers one on top of the other in stacks and arranging the stacks in rows. The storage bins or containers are accessed from the top and removed from the aisles between the rows, and many containers can be stored in a given space.

[0003] Methods for handling containers stacked in rows have been well known for several decades. Some such systems, such as that disclosed in U.S. Pat. No. 2,701,065 to Bertel, have free-standing stacks of containers arranged in rows to reduce the storage space required to store these containers, while still allowing access to specific containers as needed. Access to such desired containers can be made possible by providing a relatively complex hoisting mechanism that can be used to load and unload containers from the stacks. However, the cost of such systems makes them impractical under many circumstances, and they have been primarily commercialized for the storage and handling of large shipping containers.

[0004] The concept of using a free-standing stack of containers and providing a mechanism for retrieval and storage of specific containers has been taken further, as disclosed, for example, in EP 0 767113 B to Cimcorp. The '113 discloses a mechanism for removing a number of stacked containers using a robot load handler in the form of a rectangular tube that is lowered around the stack of containers and is configured to grip a container at any level of the stack. In this way, several containers can be lifted out of the stack as a unit. The movable tube can be used to move several containers from the top of one stack onto the top of another stack, or to move containers out of the stack or vice versa. Such a system can be useful in practice where all the containers in each stack are of the same product (known as a one-product stack).

[0005] In the system described in '113, the height of the tubes must be at least as high as the height of the maximum container stack so that a maximum container stack can be removed at one time. Thus, when used in an enclosed space such as a storehouse, the maximum stack height is limited to the height required to accommodate the tubes of the load handler.

[0006] EP 1037828 (Autostore), the contents of which are incorporated herein by reference, discloses a system in which a stack of containers is arranged within a frame structure. A system of this type is shown diagrammatically in Figures 1 to 4 of the accompanying drawings. A robotic load handler can be controllably moved around the stack on top of the stack following a track system.

[0007] One form of this robotic load handling apparatus is further described in incorporated Norwegian Patent No. 317336, the contents of which are incorporated herein by reference. Figures 3(a) and 3(b) are schematic perspective views of the load handling apparatus from the rear and front, respectively, and Figure 3(c) is a schematic perspective view of the load handling apparatus from the front lifting a container with a lid.

[0008] A further improvement to load handling equipment is described in UK Patent Application No. 1314313.6, in which each robotic handler covers only one grid space, thus allowing for a high density of load handlers and therefore a high throughput for a system of a desired size.

[0009] In some instances of such container handling systems, there may be a large number of robotic load handlers moving on a single grid. These load handlers may experience problems from time to time that may require remediation or other measures to accommodate useful service. Additionally, there may be build-up or accumulation of dirt on the grid that requires cleaning.

[0010] A drawback of the above-mentioned prior art is that in order to improve a defective load handling device or to clean the grid, the user is required to access the grid on the stack and manually carry out the necessary operations to fix or remove the load handling device or to clean the grid.

[0011] To make these operations safe, all robotic load handling equipment on a grid must be shut down before allowing user access. As the number of robotic load handling equipment in use increases and the grid becomes larger, the probability of a fault occurring increases and the severity of each fault increases with the number of units that must be shut down. Summary of the Invention

[0012] According to the present invention, there is provided a servicing apparatus for operating with a robotic picking system having two sets of rails substantially perpendicular to one another forming a grid and a robotic article handling apparatus on the grid, the servicing apparatus having a body mounted on two sets of wheels, a first set of wheels being arranged to engage at least two of the rails of the first set and a second set of wheels being arranged to engage at least two of the rails of the second set, the first set of wheels being arranged to engage at least two of the rails of the second set, the first set of wheels being arranged to engage at least two of the rails of the second set, the first set of wheels being arranged to engage at least two of the rails of the second set, the first set of wheels being arranged to engage at least two of the rails of the second set, the first set of wheels being arranged to engage at least two of the rails of the first set, the second set of wheels being arranged to engage at least two of the rails of the second set, the first set of wheels being arranged to engage at least two of the rails of the first set, the second set of wheels being arranged to engage at least two of the rails of the second set, the first set of wheels being arranged to engage at least two of the rails of the first set, the second set of wheels being arranged to engage at least two of the rails of the second set, the second set of wheels being arranged to engage at least two of the rails of the first set, the second set of wheels being arranged to engage at least two of the rails of the first set, the third set of wheels being arranged to engage at least two of the rails of the first set, the third set of wheels being arranged to engage at least two of the rails of the first set, the third set of wheels being arranged to engage at least two of the rails of the first set, the fourth ... A servicing apparatus is provided, the servicing apparatus being drivable and movable independently of the second set of wheels to enable movement of the servicing apparatus along the rails to any point on the grid by driving only the wheels, the servicing apparatus being provided with a releasable latching device which can be operated to releasably dock the servicing apparatus to a load handling apparatus located on the grid, and which is further operable to decouple the load handling apparatus from the grid so that the servicing apparatus assumes control of the load handling apparatus and moves the load handling apparatus to a predetermined location on the grid under the control of the removal system.

[0013] According to the present invention there is further provided a servicing device for operating with a robotic picking system having two sets of rails substantially perpendicular to each other forming a grid and a handling device for a robotic load on the grid, the servicing device having a body mounted on two sets of wheels, a first set of wheels arranged to engage at least two of the rails of the first set and a second set of wheels arranged to engage at least two of the rails of the second set, the wheels of the first set being drivable and movable independently of the wheels of the second set such that only one set of wheels engages the grid at a time and only the wheels of the set engaged with the rails are driven to enable movement of the servicing device along the rails to any point on the grid, the servicing device being provided with a cleaning mechanism having means for removing contamination present on the grid.

[0014] Thus, the present invention provides a system and method that overcomes the problems of the prior art and improves reliability and reduces the overall cost of a large container processing system through the use of one or more robotic service devices.

[0015] The present invention will now be described with reference to the accompanying drawings. [Brief description of the drawings]

[0016] [Figure 1] FIG. 1 is a schematic perspective view of a frame structure for housing a stack of lidded containers in a known storage system. [Diagram 2] FIG. 2 is a schematic plan view of a portion of the frame structure of FIG. [Diagram 3]Figures 3(a) and 3(b) are schematic rear and front perspective views of one form of robotic load handling apparatus for use with the frame structure of Figures 1 and 2, and Figure 3(c) is a schematic perspective view of a known load handling apparatus for use in lifting a lidded container. [Figure 4] FIG. 4 is a schematic perspective view of a known storage system having multiple load handling apparatus of the type shown in FIGS. 3(a), 3(b), and 3(c) mounted on the frame structure of FIGS. 1 and 2 together with a robotic service apparatus according to one embodiment of the present invention. [Diagram 5] FIG. 5 is a schematic perspective view of a robot service apparatus according to an embodiment of the present invention. [Figure 6] FIG. 6 is a schematic perspective view of a portion of the servicing apparatus of FIG. 5 showing a latch mechanism and a camera means disposed on the robotic servicing apparatus. [Figure 7a] FIG. 7a is a schematic side view of the robotic service device of FIGS. 5 and 6 showing the wheels, drive system, and cleaning mechanism. [Figure 7b] FIG. 7b is a schematic side view of the robotic service device of FIGS. 5 and 6 showing the wheels, drive system, and cleaning mechanism. [Figure 8] FIG. 8 is a schematic perspective view of a portion of the service apparatus of FIGS. 5 to 7 in use retrieving a malfunctioning load handling device. [Figure 9] FIG. 9 is an enlarged view of a latching mechanism suitable for latching a malfunctioning load handler to a robotic service device. [Figure 10] FIG. 10 is a schematic perspective view of a robotic servicing device according to a second embodiment of the present invention, in which the servicing device is substantially in the shape of a bridge. [Figure 11] FIG. 11 is a schematic side view of the robotic servicing device of FIG. 10 in accordance with a second embodiment of the present invention, showing the servicing device over a malfunctioning load handling device. [Figure 12]FIG. 12 is a schematic perspective view of a robot service apparatus according to a third embodiment of the present invention, in which the service apparatus is substantially U-shaped. [Figure 13] FIG. 13 is a schematic perspective view of a robotic servicing apparatus in accordance with a fourth embodiment of the present invention, with a plurality of servicing apparatuses operative to engage a malfunctioning load handling apparatus either to move it or to remove it from a grid. [Figure 14] FIG. 14 is a schematic perspective view of a robot service apparatus according to a fourth embodiment of the present invention, showing a plurality of service apparatuses of different configurations. [Figure 15] FIG. 15 is a schematic perspective view of a robot service apparatus according to a fourth embodiment of the present invention, showing a further configuration of a plurality of service apparatuses. [Figure 16] FIG. 16 is a schematic perspective view of a robot service apparatus according to a fifth embodiment of the present invention, in which the service apparatus is provided with a seat capable of carrying a passenger or user. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] As shown in Figures 1 and 2, stackable containers known as lidded bins 10 are stacked on top of one another to form a stack 12. The stacks 12 are arranged in a grid-like frame structure 14 at a storage or manufacturing site. Figure 1 is a schematic perspective view of the frame structure 14, and Figure 2 is a top view of a single stack 12 of lidded bins 10 arranged within the frame structure 14. Each lidded bin 10 typically holds a number of articles of manufacture (not shown), which may be the same or different types of products depending on the application.

[0018] The frame structure 14 includes a plurality of upright members 16 supporting a plurality of horizontal members 18, 20. A first set of parallel horizontal members 18 are arranged perpendicular to a second set of parallel horizontal members 20 to form a horizontal grid structure supported by the upright members 16. The members 16, 18, 20 are typically made of metal. The containers 10 are stacked between the members 16, 18, 20 of the frame structure 14 such that the frame structure 14 prevents horizontal movement of the stack 12 of containers 10 and vertical movement of the containers 10.

[0019] The top level of the frame structure 14 includes rails 22 arranged in a grid pattern across the top surface of the stack 12. With further reference to Figures 3 and 4, the rails 22 support a plurality of robotic load handling devices 30. A first set 22a of parallel rails 22 guides movement of the load handling devices 30 in a first direction (X) across the top surface of the frame structure 14, and a second set 22b of parallel rails 22 perpendicular to the first set 22a guides movement of the load handling devices 30 in a second direction (Y) perpendicular to the first direction. In this manner, the rails 22 allow movement of the load handling devices 30 in two directions in the XY plane, such that the load handling devices 30 may be moved to a position above any stack 12.

[0020] Each load handling device 30 has a car body 32 arranged to run in the X and Y directions on the rails 22 of the frame structure 14 above the stack 12. A first set of wheels 34, consisting of a pair of wheels 34 at the front of the car body 32, and a pair of wheels 34 at the rear of the car body 32, are arranged to engage two adjacent rails of the first set 22a of the rails 22. Similarly, a second set of wheels 36, consisting of a pair of wheels 36 on each side of the car body 32, are arranged to engage two adjacent rails of the second set 22b of the rails 22. Each set of wheels 34, 36 can be raised and lowered so that either the first set of wheels 34 or the second set of wheels 36 can engage the respective set of rails 22a, 22b at any one time.

[0021] When the first set of wheels 34 are engaged with the rails of the first set 22a and the second set of wheels 36 are securely raised from the rails 22, the wheels 34 can be driven by a drive mechanism (not shown) housed in the car body 32 to move the load handling apparatus 30 in the X direction. To move the load handling apparatus 30 in the Y direction, the first set of wheels 34 are securely raised from the rails 22 and the second set of wheels 36 are lowered into engagement with the second set of rails 22a. Thus, the drive mechanism can be used to drive the second set of wheels 36 to effect movement in the Y direction.

[0022] In this manner, one or more robotic load handlers 30 may move around the top surface of each of the stacks 12 on the frame structure 14 under the control of a central pick-up system (not shown). Each robotic load handler 30 is provided with means for lifting one or more receptacles or containers from the stack to access the required products. In this manner, multiple products may be accessed from multiple locations within the grid and stack at one time.

[0023] 4 shows a representative storage system as described above, including a plurality of load handling devices 30 movable relative to the stack 12. Additionally, a robotic servicing device is positioned on the grid 14.

[0024] It will be appreciated that any form of load handling equipment 30 may be used, and the robotic service equipment may be appropriately adapted to interact with such load handling equipment 30.

[0025] A first embodiment of the second type of service device 50 is described below with reference to Figures 5 to 7.

[0026] Referring to FIG. 5, a service apparatus 50 includes a body 52 having first and second sets of wheels 54, 56 engageable with the first and second sets 22a, 22b of rails 22, respectively.

[0027] The service apparatus 50 includes additional components in addition to those of the robotic load handling apparatus 30. As can be seen from Figures 5 and 6, the apparatus 50 includes a releasable latch mechanism 58 and a camera means 60. The apparatus 50 further includes cleaning means such as a vacuum cleaning system 64 and a brush mechanism 52 mounted adjacent each set of wheels 54, 56. The apparatus 50 further includes a spray device 66 capable of dispensing a suitable cleaning agent under the control of a central pick-up system (not shown).

[0028] Similar to the operation of the load handling apparatus 30, the first and second wheels 54, 56 of the servicing apparatus 50 may be moved vertically relative to the car body 52 to engage and disengage with the corresponding sets of rails 22a, 22b. By engaging and driving the appropriate sets of wheels 54, 56, the servicing apparatus 50 may be moved in the X and Y directions in a horizontal plane on the frame structure 14.

[0029] In the event of a failure or inoperability of the robotic load handling equipment 30a, the servicing equipment 50 can be moved on the grid 14 to a location near the inoperable equipment 30a. Then, upon approaching the inoperable equipment 30a, the camera means 60 of the servicing equipment 50 can be used to view the situation from a control position (not shown). When the load handling equipment 30a requires removal from the grid 14, the servicing equipment 50 can be releasably latched to the inoperable load handling equipment 30a, as shown in FIG. 8. The servicing equipment 50 can then be used to guide the inoperable equipment 30a to a location where it can be repaired or removed completely from the grid 14.

[0030] Although the required configuration of the releasable latch mechanism 58 is not as shown in Figures 5-9, it will be appreciated that any suitable form of releasable latch mechanism may be used. The latch mechanism 58 may be connected to the defective robotic handling device and may lift it completely off the grid or move the defective device's set of wheels up or down so that it can be pushed, pulled or dragged to a desired location. The latch mechanism 58 may also include a device that allows the gripper mechanism of the defective unit to be retracted from the grid or other mechanical or electrical interaction with the robotic load handling device 30.

[0031] Furthermore, the service device 50 may be provided with sensor means instead of or in addition to the camera means 60. For example, the service device 50 may be provided with sensors that allow a system operator to remotely diagnose a malfunction with a broken or stalled robotic load handling device 30. This may include, but is not limited to, electrical connection means to ports of the robotic load handling device 30 to check or diagnose the malfunction via an on-board diagnostic system. This may also include sensors such as ultrasonic detectors, x-ray cameras, or sensors for evaluating the data communication functions within the load handling device 30.

[0032] Furthermore, the servicing device 50 may comprise a resetting means, either instead of or in addition to the sensor, so that the servicing device 50 can reset the robotic load handling device 30. The resetting means may comprise a remotely operated manipulator device or may comprise a remotely operated electrical reset device. A mechanical manipulator may also be remotely operable to push the load handling device 30 when the diagnostics indicate that the load handling device 30 is only temporarily loaded on a portion of the grid. Alternatively, a mechanical device may work in conjunction with the servicing device 50 to push the load handling device to a different position on the grid or completely off the grid.

[0033] In another use of the robotic servicing device 50, the device 50 may run on the grid 14 to stabilize the condition of the grid 14. For example, spills or dust may accumulate on the grid 14 over time. The servicing device 50 may be provided with a traction measurement system so that, for example, in case of spills and thus loss of traction for the robotic handler 30 on the grid 14, one or more wheels 56 are driven while one or more wheels 54 are braked to obtain stability. For this purpose, the servicing device 50 may be deployed on the grid 14 and the camera means 60 may be used to remotely view the condition of the grid 14. The brush mechanism 62, the cleaning agent dispensing means 66 and the vacuum system 66 may thus be used appropriately to clean the grid 14.

[0034] A spill of a product such as oil on the grid that would make the grid slippery can be detected by a typical robotic load handler using wheel slippage detection. At this time, it is important to immediately treat the spill to prevent the oil from spreading over a large portion of the grid. The proposed method uses some aspect of robotic servicing to treat the spill. In use, the robotic device causing the spill is stopped. Other robotic devices within a predetermined radius of the potential spill are also stopped. The pick control system can be used to block all of the potentially affected areas of the grid in software so that other robotic devices 30, 50 cannot access the affected areas. One or more robotic servicing devices can then be deployed to first clean the area around the now stationary robotic device. The drive mechanism of the deployed servicing device 50 can then be used to measure traction so that the spill is properly removed. The robotic load handling device 30 can then be used to pick up and remove the affected robotic load handling device 30 to a maintenance area so that the wheels can be cleaned. Additional robotic service devices can be deployed to finish cleaning the affected area until there is sufficient traction on all parts of the grid.

[0035] Additionally, the robotic service apparatus 50 may be provided with means for assessing the condition of the tracks and grid. For example, the service apparatus 50 may use the sensor or camera means described above to assess the condition of the grid in addition to or alternatively to assessing the condition of the robotic load handling apparatus 30. For example, the robotic service apparatus may be deployed on the grid during a housekeeping phase to ensure the stability and integrity of the tracks and grid.

[0036] It will be understood that the service device 50 may include all, one, or any combination of the components described above, and that it is not essential to the present invention to have all of the sensors and components described above. Figures 10 and 11 show a second embodiment of the present invention. Components similar to those described with reference to the first embodiment are labeled with the same reference numerals.

[0037] FIG. 10 illustrates a different configuration of a robotic service apparatus 150. The robotic service apparatus 150 includes a body 152 that is substantially bridge-shaped. Referring to FIGS. 10 and 11, the robotic service apparatus 150 includes a body 152 that includes first and second sets of wheels 154, 156 that are engageable with the rails 22 of the first and second sets 22a, 22b, respectively. The bridge-shaped body 152 is sized to straddle the load handling apparatus 30. The service apparatus 150 includes a releasable latch or hook mechanism 158 that is deployable from the underside of the bridge portion.

[0038] In use, the first and second sets of wheels 154, 156 of the robotic service device 150 can be moved vertically relative to the body 152 to engage and disengage the wheels 154, 156 from the corresponding sets of rails 22a, 22b. By engaging and driving the appropriate sets of wheels 154, 156, the robot 150 can be moved in the X and Y directions in a horizontal plane on the top surface of the frame structure 14.

[0039] In this manner, the service apparatus 150 can be deployed on the grid 14 and driven to any desired point, where it straddles the malfunctioning load handling apparatus 30 so that the hook mechanism 158 can be used to lift the malfunctioning apparatus 30 from the grid 14. The removal control system can then be used to move the service apparatus 150 to a predetermined position on the grid 14, where the malfunctioning load handling apparatus 30 can be removed, if desired. Although not shown in the drawings, it will be appreciated that the service apparatus of this second embodiment can also include the components described with reference to the first embodiment. These components include, but are not limited to, the brush mechanism 62, the vacuum system 64, the spray system 66, the traction measurement system, and the camera means 60, all of which operate in a manner similar to that described above.

[0040] A third embodiment of the present invention is shown in Figure 12. Components similar to those described with reference to the first and second embodiments of the present invention are given the same reference numerals.

[0041] 12, the robot 250 includes a body 252 having first and second sets of wheels 254, 256 engageable with the rails 22 of the first and second sets 22a, 22b, respectively, of the grid 14. The U-shaped body 252 is sized to enclose the load handling device 30. The service device 250 is provided with a releasable latch or hook mechanism 258 deployable from within the U-shaped portion.

[0042] In use, the first and second sets of wheels 254, 256 of the robotic service apparatus 250 can be moved vertically relative to the body 252 to engage and disengage the wheels 254, 256 from the corresponding sets of rails 22a, 22b. By engaging and driving the appropriate set of wheels 254, 256, the robotic service apparatus 250 can be moved in the X and Y directions in a horizontal plane on the top surface of the grid 14.

[0043] In this way, the service device 250 can be deployed on the grid 14 and driven to any desired point, where it surrounds the malfunctioning load handling device 30 so that the latch or hook mechanism 258 can be used to pull, push or otherwise manipulate the malfunctioning device 30. The removal control system can then be used to move the service device 215 to a predetermined position on the grid 14, where the malfunctioning load handling device 30 can be removed as required. Although not shown in the drawings, it will be appreciated that the service device of this third embodiment can also include the components described with reference to the first and second embodiments. These components include, but are not limited to, the brush mechanism 62, the vacuum system 64, the spray system 66, the traction measurement system and the camera means 60, all of which operate in a manner similar to that described above.

[0044] It will be appreciated that the latching means need not necessarily be in the form of a hook, but any suitable latching means may be used. For example, the latching means may be magnetic or electromagnetic. Furthermore, the latching means may be located anywhere on the service equipment and multiple latch mechanisms may be used on all sides of the service equipment so that load handling equipment may be approached and latched from any direction on the grid.

[0045] Additionally, the latch mechanism of the servicing device may interact with the load handling device in a manner suitable for removing the load handling device from the grid. There may be any form of electrical communication or mechanical interaction between the servicing device and the load handling device to remove the load handling device from the grid. 13-15 show a further embodiment of a robotic service machine 50. Components similar to those described with reference to the previous embodiment of the present invention are labeled with the same reference numerals.

[0046] 13, a pair of robotic servicing machines 450 are shown connected by suitable members 452 that allow the two separate robotic servicing machines 450 to function as a single unit. Members 452 are further provided with connecting, latching and lifting means 454, 456.

[0047] The interconnected robotic service devices 450 are remotely operated into position so that they occupy spaces in the grid near the malfunctioning load handling device 30. From this position, the latching means 454 can be lowered or adjusted to engage with cooperating latching points 456 on the robotic load handling device 30. Once engaged, the lifting means 456 is operated to sufficiently lift the malfunctioning load handling device 30 off the grid and track. Once sufficiently lifted, the connected robotic service devices 450 are remotely commanded to move into position in the grid to allow repair of the robotic handling device.

[0048] 14 and 15 show different configurations of the robotic servicing apparatus 450 connected together and different locations of the member 452 and the connecting latch and lifting means 454, 456.

[0049] It will be appreciated that in this embodiment of the present invention, the robotic servicing apparatus 450 is connected to the load handling apparatus 30 by a rigidly mounted coupling, allowing the robotic load handling apparatus to be approached and lifted from any point on the grid, including any corner, edge, or nearby support structure.

[0050] It will be appreciated that the configurations shown in Figures 13-15 are just a few of many possible configurations, and the invention of the fourth embodiment is not limited to these configurations. The connecting, latching and lifting means may be a single configuration or three separate configurations. The connecting and latching mechanism may include mechanical, magnetic or electromagnetic means, or other suitable means. The lifting means may include a winch means 458 or any suitable lifting means.

[0051] 16, the service apparatus 350 has a substantially flat body 352 with first and second sets of wheels 354, 356 engageable with the first and second sets 22a, 22b, respectively, of rails 22 of the grid 14. The flat body 352 is provided with seating means 353 so that it can carry a user. The service apparatus 350 can be remotely controlled by the control of the retrieval system, but can also be driven manually by a user (not shown).

[0052] In use, the first and second wheels 354, 356 of the servicing apparatus 350 may be moved vertically relative to the car body 352 such that the wheels 354, 356 engage and disengage the corresponding sets of rails 22a, 22b. By engaging and driving the appropriate sets of wheels 354, 356, the servicing apparatus 350 may be moved in the X and Y directions in a horizontal plane above the grid 14.

[0053] In this manner, the service device 350 is positioned on the grid 14 and driven to predetermined points on the grid where maintenance is to be performed.

[0054] Although not shown in the drawings, it will be appreciated that the service apparatus 350 of the fifth embodiment may also include the components described with reference to the first, second, third and fourth embodiments, including, but not limited to, the brush mechanism 62, the vacuum system 64, the spray system 66, the traction measurement system and the camera means 60, all of which operate in a manner similar to that described above.

[0055] In this way, the integrity of a large robotically controlled unloading system can be maintained, malfunctioning load handling equipment can be salvaged, or spills on the grates can be cleaned up without shutting down the entire system. In systems of any size, this can represent a substantial reduction in system downtime.

[0056] Furthermore, the robotic service apparatus described in any or all of the above embodiments can be adapted to support equipment (not shown) such as a barrier, for example, to allow the remotely operable mechanical handling means to place a barrier around a portion of the grid for safety reasons if the operator needs to be on top of the grid.

[0057] It will be appreciated that a robotic service device as described above may include one or all of the components described above. For example, the service device may lift a malfunctioning load handling device off of a grid and remove it to a maintenance station on the grid that also includes a towing monitoring means and a cleaning means. Additionally, a rider-on service device may also be provided with means for pulling a malfunctioning load handling device off of the grid.

[0058] Additionally, the robotic service apparatus 50 may have a load carrying portion similar to the load handling apparatus, which may be configured with maintenance and cleaning facilities as described above, and which may be interchangeable such that a service apparatus may perform different functions depending on the load carrying portion previously installed.

[0059] It will be appreciated that the robotic load handling apparatus 30 may be configured as a cantilever as shown in Figures 1-4, occupying two grid spaces, or alternatively, the robotic load handling apparatus 30 may be configured as shown in Figures 13-15, occupying only a single grid space.

[0060] Many variations and modifications, not specifically described, may also be possible without departing from the scope of the present invention as defined in the appended claims.

Claims

1. 1. A service apparatus for operating with a robotic picking system having two sets of substantially orthogonal rails forming a grid, and a robotic load handling apparatus on the grid, comprising: The servicing device has a body mounted on two sets of wheels, a first set of wheels arranged to engage at least two of the rails of a first set and a second set of wheels arranged to engage at least two of the rails of a second set, the first set of wheels being drivable and movable independently of the second set of wheels such that only one set of wheels is previously engaged with the grid, and only the wheels of the set engaged with the rails are driven to allow movement of the servicing device along the rails to any point on the grid; and the servicing apparatus is provided with a releasable latching device operable to releasably dock the servicing apparatus to load handling apparatus located on the grid; and The latch device is further operable to decouple the load handling device from the grid such that the servicing device assumes control of the load handling device and moves the load handling device to a predetermined location on the grid under control of the removal system.

2. 2. The servicing apparatus of claim 1, wherein said latching means includes means for positively lifting the load handling apparatus from the rails and moving the load handling apparatus into position on said grid.

3. 2. The servicing apparatus of claim 1, wherein the latching device has means for releasably docking the servicing apparatus to the load handling apparatus, and the servicing apparatus further has means for releasing both sets of wheels from the rails of the pick system so that the servicing apparatus can push or pull the load handling apparatus into position on the grid.

4. 4. A service apparatus as claimed in any one of claims 1 to 3, further comprising a traction measurement system comprising drive means for driving one set of wheels engaged with the grid whilst disengaging the other set of wheels from the grid, the drive means being controlled by suitable electronic control means.

5. 5. A service device as claimed in claim 4, wherein the electronic control means comprises means for monitoring the rotation of all sets of wheels so that the traction of the wheels on the grid can be measured, said measurement being compared with predetermined traction data to effect the required grid cleaning.

6. 6. The servicing apparatus of any one of claims 1 to 5, further comprising a cleaning apparatus.

7. 7. The service device of claim 6, wherein the cleaning device comprises a vacuum cleaner and / or a number of brushes and / or spray devices configured to treat spills on the grate.

8. 8. A servicing apparatus according to any preceding claim, further comprising camera means providing a vision system by which a user can remotely view the robotic load handling apparatus or grid.

9. 9. A servicing apparatus as claimed in any one of claims 1 to 8, further comprising seat means suitable for a user so that the servicing apparatus can be used in situ in the event that manual intervention is required on the grid.

10. 1. A service apparatus for operating with a robotic picking system having two sets of substantially orthogonal rails forming a grid, and a robotic load handling apparatus on the grid, comprising: The servicing device has a body mounted on two sets of wheels, a first set of wheels arranged to engage at least two of the rails of a first set and a second set of wheels arranged to engage at least two of the rails of a second set, the first set of wheels being drivable and movable independently of the second set of wheels such that only one set of wheels is engaged with the grid at a time and only the wheels of the set engaged with the rails are driven to allow movement of the servicing device along the rails to any point on the grid; and The service device is provided with a cleaning mechanism having means for removing contamination present on said grid.

11. 11. The service device of claim 10, wherein the cleaning mechanism comprises a vacuum cleaner and / or a number of brushes and / or spray devices configured to treat spills on the grate.

12. 12. The service apparatus of claim 11, further comprising camera means for providing a vision system by which a user can remotely view the robotic load handling apparatus or grid.

13. The service apparatus is further provided with a releasable latching device operable to releasably dock the service apparatus to a load handling apparatus located on the grid; and 13. A servicing apparatus as claimed in any one of claims 11 to 12, wherein the latching device is further operable to decouple the load handling apparatus from the grid so that the servicing apparatus assumes control of the load handling apparatus and moves the load handling apparatus to a predetermined location on the grid under the control of the removal system.

14. 14. A servicing apparatus as claimed in claim 13, wherein said latching means includes means for positively lifting the load handling apparatus from the rail and moving the load handling apparatus into position on said grid.

15. 14. The servicing apparatus of claim 13, wherein the latching device has means for releasably docking the servicing apparatus to the load handling apparatus, and the servicing apparatus further has means for releasing both sets of wheels from the rails of the pick system so that the servicing apparatus can push or pull the load handling apparatus into position on the grid.

16. 16. A service apparatus as claimed in any one of claims 10 to 15, further comprising a traction measurement system comprising drive means for driving one set of wheels engaged with the grid whilst disengaging the other set of wheels from the grid, the drive means being controlled by suitable electronic control means.

17. 17. A service device as claimed in claim 16, wherein the electronic control means comprises means for monitoring the rotation of all sets of wheels so that the traction of the wheels on the grid can be measured, said measurement being compared with predetermined traction data to effect the required grid cleaning.

18. 18. A service station as claimed in any preceding claim, further comprising seating means to enable a user to move over the grid to perform maintenance or viewing functions.

Images