Storage box transfer robot

Abstract

To provide a remote control carrier suitable for picking up a storage box from a storage system located under it.SOLUTION: A remote control carrier comprises: driving means 19 located in or at least partly in rolling means 10 of the carrier, and providing a driving force specific to a rolling set to the carrier in a first direction or a second direction; and motor controlling electronic means configured to supply power to load carrying rolling means.SELECTED DRAWING: Figure 9

Description

[Technical field]

[0001] The present invention relates to a remotely operated vehicle or robot for picking up storage boxes from a storage system as defined in the preamble of claim 1, and to a storage system for storing the boxes. [Background technology]

[0002] Remotely operated vehicles are known for picking up storage bins from a storage system. A detailed description of a relevant prior art storage system is presented in WO 98 / 49075 and details of a prior art vehicle suitable for such a storage system are disclosed in detail in Norwegian Patent No. 0317366. Such prior art storage systems comprise a three-dimensional storage grid that accommodates storage bins stacked on top of one another to a certain height. The storage grid is typically constructed as an aluminium row interconnected by a top rail on which a number of remotely operated vehicles, or robots, are arranged to move laterally. Each vehicle is equipped with a lift for picking up, transporting and placing the bins to be stored in the storage grid, and with a rechargeable battery for powering a motor integrated in the vehicle. The vehicles typically communicate with a control system via a wireless link and are recharged, when necessary, typically overnight, at a charging station.

[0003] An example of a prior art storage system is shown in Figure 1. The storage system 3 includes a number of transporters or robots 1 configured to move in X and Y directions (referring to a Cartesian coordinate system 100) on dedicated support rails 13 and to receive storage boxes 2 from storage rows in a box storage grid 15. The prior art storage system 3 may also include a dedicated box lift device 50 arranged to receive the storage boxes 2 from the transporters 1 at the top level of the storage system 3 and transport the storage boxes 2 vertically down to a delivery station or port 60.

[0004] However, in this known system, each vehicle covers a cross section equivalent to two storage rows of the underlying storage system, thereby limiting the maximum number of vehicles operating simultaneously. Summary of the Invention [Problem to be solved by the invention]

[0005] It is therefore an object of the present invention to provide a transport and storage system that allows for a significant increase in the number of transports operating simultaneously while still providing successful handling of storage boxes. [Means for solving the problem]

[0006] The invention is set forth and characterized in the main claim, while further characteristics of the invention are described in the dependent claims. In particular, the present invention relates to a remote-operated carrier for picking up a storage box from an underlying storage system, comprising a lifting device suitable for lifting the storage box from the underlying storage system, a first carrier rolling means comprising a first rolling set and a second rolling set arranged on opposite side walls of the carrier body and enabling, in use, movement of the carrier along a first direction (X) on the underlying storage system, and a second carrier rolling means comprising a first rolling set and a second rolling set arranged on opposite side walls of the carrier body and enabling, in use, movement of the carrier along a second direction (Y) perpendicular to the first direction (X) on the underlying storage system, each of said rolling sets comprising at least two wheels. The first and second rolling sets may be supported by belts, chain tracks or other rolling means enabling forward and / or rearward movement of the carrier on the underlying storage system. Any other feature or combination of features may also be included.

[0007] The transport further comprises a first drive means located on or at least partially within the first transport rolling means and suitable for providing a rolling set specific drive force to the transport in a first direction (X), a second drive means located on or at least partially within the second transport rolling means and suitable for providing a rolling set specific drive force to the transport in a second direction (Y), and motor control electronics arranged in a volume between two of the wheels of the respective rolling sets, the motor control electronics being configured to supply power to the first and second transport rolling means. In use, at least one of the first and second transport rolling means is in contact with an underlying storage system.

[0008] In an advantageous embodiment, at least one of the drive means comprises an electric motor using permanent magnets, such as a brushless electric DC (direct current) motor. In another advantageous embodiment, at least one of the first and second drive means comprises a rotor magnet arranged on an inner surface of the outer periphery of the corresponding respective carrier rolling means.

[0009] In another advantageous embodiment, at least one of the first and second drive means comprises a stator arranged at least partially, preferably completely, in the same rotation plane as the carrier rolling means and at least partially, preferably completely, in the carrier body, whereby the rotation plane means in this embodiment the plane extending at right angles from the rotation axis of the carrier rolling means.

[0010] In another advantageous embodiment, the vehicle comprises means suitable for (at least indirectly) measuring the electromotive force (emf) of at least one vehicle rolling means, in signal communication with one of the stator and rotor, thereby enabling rolling set-specific speed registration of the vehicle during operation. For example, a back-emf measuring circuit may be placed in signal communication with the vehicle rolling means. Alternatively or in combination, Hall sensors may be used.

[0011] In another advantageous embodiment, the carrier comprises a rotary encoder (at least indirectly) connected to at least one of the first and second carrier rolling means, thereby enabling angular position feedback during operation. Such a rotary encoder is suitable for converting the angular movement of the carrier rolling means into an analog or digital code. The rotary encoder (or shaft decoder) may be of the type of absolute rotary encoder and / or absolute multi-turn encoder. Said absolute rotary encoder may be at least one of a mechanical encoder, an optical encoder, a magnetic encoder and a capacitive encoder. Furthermore, the absolute multi-turn encoder may be at least one of a battery-powered multi-turn encoder, a gear-powered multi-turn encoder and a self-powered multi-turn encoder.

[0012] In another advantageous embodiment, the rotary encoder is a rotary encoder disk arranged within the outer periphery of at least one of the first and second carrier rolling means, preferably between the outer periphery and the rotor magnet.

[0013] In another advantageous embodiment, the carrier further comprises means suitable for measuring the acceleration of at least one of the first and second carrier rolling means, in signal communication with the stator. Such means preferably comprise one or more piezoelectric sensors, for example an accelerometer from PCB™ Piezotronics. As an alternative to piezoelectric sensors , or in combination with a piezoelectric sensor, one or more inductive sensors may be used.

[0014] In another advantageous embodiment, each rolling set comprises at least two wheels and the vehicle further comprises motor control electronics arranged in a volume between two of the wheels of the respective rolling set, said motor control electronics being in this embodiment configured to provide power to the first and second vehicle rolling means and preferably also capable of transmitting communication signals.

[0015] In another advantageous embodiment, the first carrier rolling means comprises four X-wheels having their direction of rotation in a first direction, and the second carrier rolling means comprises four Y-wheels having their direction of rotation in a second direction, each of the X-wheels and each of the Y-wheels being drivingly connected to the first drive means and the second drive means, respectively. Each of the wheels comprises a rotor magnet, preferably a plurality of rotor magnets (e.g. in the form of rotor magnet disks) arranged within the inner surface of the outer circumference of the wheel, and a plurality of stators (e.g. in the form of stator disks) arranged at least partially, e.g. completely, within the carrier body, preferably at the same or approximately the same height as the position of the rotation axis of the wheel. In this embodiment, the height refers to the distance from the highest point of the storage system below during use. The said stator includes both a winding and a yoke, the stator field winding following the outer circumference of the wheel.

[0016] In another advantageous embodiment, at least a part, preferably the entire drive means is arranged within the outer periphery of the wheel. For example, if four belts are applied to drive the vehicle of the present invention in the X and Y directions, a total of four motors may be placed in operative engagement with each of the four belts to achieve the desired rolling set specific driving force. Similarly, if eight wheels are applied to drive the vehicle in the X and Y directions, a total of eight motors may be placed in operative engagement with each of the eight wheels to achieve the desired rolling set specific driving force.

[0017] The invention also relates to a storage system suitable for storing boxes, comprising a box storage structure with a number of storage rows, each storage row arranged to receive vertically stacked storage boxes, and a remote-operated carrier according to any of the above mentioned embodiments.

[0018] In the following description, specific details are introduced to provide a thorough understanding of embodiments of the claimed transport and storage systems. However, those skilled in the art will understand that these embodiments may be practiced without one or more of the specific details, or with other components, systems, etc. In other instances, well-known structures or operations are not shown or described in detail to avoid obscuring aspects of the disclosed embodiments. [Brief description of the drawings]

[0019] [Figure 1] FIG. 1 is a perspective view of a prior art storage system including a grid and multiple remotely operated vehicles / robots. [Diagram 2] FIG. 2 is a top perspective view of a remotely operated vehicle according to one embodiment of the present invention. [Diagram 3] FIG. 3 is a bottom perspective view of the carrier of FIG. 2. [Figure 4] 4 is a cross-sectional view of the carrier of FIGS. 2 and 3 taken along one major orientation of the carrier. FIG. [Diagram 5] FIG. 2 is a perspective view of a storage system from above according to one embodiment of the present invention, in which a carrier of the present invention is shown positioned directly above five adjacent storage rows. [Figure 6] Figure 6A is a cross-sectional view of the storage system of Figure 5 showing carriers of the present invention on adjacent rows along one main orientation of the carriers, and Figure 6B is a cross-sectional view of the storage system of Figure 5 showing carriers of the present invention on adjacent rows along another main orientation of the carriers. [Figure 7] FIG. 1 is a perspective view of a rolling set forming part of a carrier according to one embodiment of the present invention; [Figure 8] 8A and 8B are perspective views of a wheel that forms part of a transport device according to one embodiment of the present invention; [Figure 9] Figure 9A shows the rolling set of Figure 7 with one of the wheels removed, and is a cross-sectional view of the rolling set taken along one main orientation of the carrier. Figure 9B shows the rolling set of Figure 7 with one of the wheels removed, and is a cross-sectional view of the rolling set taken along another main orientation of the carrier. Figure 9C shows the rolling set of Figure 7 with one of the wheels removed, and is a perspective side view of a portion of the rolling set with the wheel removed. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] All relative terms such as up, down, sideways, vertical, X-direction, Y-direction, Z-direction, etc. used to describe the vehicle of the present invention (hereafter referred to as the robot) shall be interpreted using the prior art storage system referred to above (FIG. 1) as a reference system. For clarity, the X, Y, and Z directions are indicated in FIGS. 1-7 and 9 by a Cartesian coordinate system 100.

[0021] 2 and 3 provide perspective views from two different angles of the robot 1, which comprises a rectangular carrier body or framework 4 presenting inside a centrally located cavity, a top lid 72 covering the upper part of the body 4, a first carrier rolling means 10 with four X wheels 101-104 for moving in the X direction on the support rails 13 of the underlying box storage grid 15, and a second carrier rolling means 11 with four Y wheels for moving in the Y direction on the support rails 13 of the underlying box storage grid 15, both the first and second rolling means 10, 11 being attached to the outer wall of the body 4. The size of the cavity in the robot 1 (FIG. 3) is adapted to accommodate at least the main part, and most preferably the entire box, constituting the largest storage box 2 intended to be picked up by the robot 1. The operation of picking up the storage box 2 is performed by a lifting device 7 shown in a retracted position at the upper end of the cavity in FIG. 3.

[0022] FIG. 4 shows a cross-sectional view of the robot 1 as viewed along the X direction. 5 and 6 show a portion of a storage system 3 in which robots 1 are positioned in various adjacent positions on top of a bin storage grid 15. In four of the five positions, the robots 1 are positioned directly above a storage row of the grid 15. As is most evident in FIGS. 6A and 6B, which show the storage system 3 of FIG. 5 in cross-section along the Y and X directions, respectively, the robots 1 are dimensioned such that their maximum cross-sectional area along the XY plane occupies less than or equal to the cross-sectional area of ​​the corresponding (underlying) storage row. Thus, two or more robots 1 can operate simultaneously over adjacent rows of the grid 15, freeing up more space compared to prior art systems.

[0023] One side of the first carrier rolling means 10 is shown in a perspective side view in Figure 7. The rolling means 10, in this particular embodiment of the invention, comprises two wheels 101, 102 with outer rims / edges 9 located along the X direction near the corners of the carrier body 4. A cover plate 25, which forms part of the carrier body 4, is arranged between the two wheels 101, 102.

[0024] Further details of one of these wheels 101, 102 are provided in Figures 8A and 8B, showing the outer and inner faces, respectively. In Figure 8B, the optical rotary orthogonal optics A rotary encoder 23 of the type of encoder is disposed within the inner radial surface of the outer rim 9. Other types of encoders may be used such as magnetic encoders, linear encoders, voltage-based analog encoders, etc. The rotor 5 in FIG. 8, shown as a set of permanent magnets 5, is disposed inside the periphery defined by the rotary encoder 23, i.e. closer to the axis of rotation of the wheel 101.

[0025] The corresponding stator 19 is shown in Figure 9 with electrical windings 19a wound around a yoke 19b, however, those skilled in the art will appreciate that the stator 19 and rotor 5 may (in other embodiments of the invention) be comprised of stator magnets and rotor yoke / windings, respectively.

[0026] Figures 9B and 9C also show an arrangement in which the means for measuring acceleration 24 are connected in signal communication with the stator 19 of each wheel 101, 102, for example by using a piezoelectric sensor. Figure 9A is a cross-sectional view of a portion of the first vehicle rolling means 10 along the X direction, showing the stator 19 surrounded by the outer rim 9.

[0027] All components and their interactions / configurations are valid for the second vehicle rolling means 11 as well. The arrangement of the drive means 5, 19 close to or within the rolling means 10, 11 of the robot 1 contributes to freeing up space on the storage system during operation, thereby allowing the design of a more compact robot 1 compared to prior art robots.

[0028] All operations of the robot 1 are controlled by the wireless communication means and the remote control unit. This includes one or more of: controlling the robot movement, controlling the carrier lift device 7, measuring the robot position, measuring the robot velocity, and measuring the robot acceleration.

[0029] In the above description, various aspects of the carrier and storage system according to the present invention have been described with reference to embodiments. For purposes of explanation, the system and configurations have been described to provide a thorough understanding of the system and its workings. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiments, as well as other embodiments of the system, will be apparent to those skilled in the art to which the disclosed subject matter pertains, and are deemed to be within the scope of the present invention. [Explanation of symbols]

[0030] 1 Remotely operated vehicles / robots 2 Storage box 3. Storage System 4. Carrier body / framework 5 Rotor / permanent magnet 7 Lifting device 9 Outer Rim / Outer Circumference of Rolling Means 10 First vehicle rolling means / first wheel set 11 Second vehicle rolling means / second wheel set 13 Support Rail 15 box storage lattice 19 Stator 19a Winding 19b York 23 Rotary Encoder 24 Means for measuring acceleration / piezoelectric sensor 25 Cover plate 50 Box Lifting Device 60 Shipping Stations / Ports 72 Top lid 100 Cartesian Coordinate System 101 1st X Wheel 101 2nd X Wheel 102 3rd X-Wheel 103 4th X-Wheel 111 1st Y Wheel 112 2nd Y Wheel 113 3rd Y Wheel 114 4th Y Wheel

Claims

1. A remotely operated carrier (1) for picking up a storage box (2) from an underlying storage system (3), comprising: a carrier lift device (7) for lifting said storage box (2) from said underlying storage system (3); a first carrier rolling means (10) comprising a first set of rolls (101-102) and a second set of rolls (103-104) arranged on opposite side walls of a carrier body (4) and enabling, in use, movement of said carrier (1) along a first direction (X) over said underlying storage system (3); a second carrier rolling means (11) comprising a first set of rolls (111-112) and a second set of rolls (113-114) arranged on opposite side walls of said carrier body (4) and enabling, in use, movement of said carrier (1) along a second direction (Y) perpendicular to said first direction (X) on said underlying storage system (3); A remote-controlled vehicle (1), wherein each of said rolling sets comprises at least two wheels (101-104, 111-114), a first drive means (5, 19) located on or at least partially within said first carrier rolling means (10) for providing a rolling set specific drive force to said carrier (1) in said first direction (X); second drive means (5, 19) located on or at least partially within said second carrier rolling means (11) for providing a rolling set-specific drive force to said carrier (1) in said second direction (Y); motor control electronics arranged in a volume between two of said wheels of each rolling set (101-104, 111-114), configured to supply power to said first and second vehicle rolling means (10, 11); The remote controlled vehicle (1) further comprises:

2. 2. A vehicle (1) according to claim 1, characterized in that at least one of the drive means (5, 19) comprises an electric motor (5, 19) using permanent magnets (5).

3. 3. The vehicle (1) according to claim 1 or 2, characterized in that at least one of the first and second drive means (5, 19) comprises a rotor magnet (5) arranged on an inner surface of the outer periphery (9) of the vehicle rolling means (10, 11).

4. 4. The carrier (1) according to claim 2 or 3, characterized in that said at least one of the first drive means (5, 19) and the second drive means (5, 19) comprises a stator arranged at least partially in the same rotation plane as the carrier rolling means (10, 11) and at least partially within the carrier body (4).

5. At least one of the first and second drive means (5, 19) comprises an electric motor (5, 19) comprising a rotor (5) and a stator (19); The carrier (1) and means (24) for measuring the back electromotive force, in signal communication with one of said stator (19) and said rotor (5) to enable rolling set specific speed registration of said vehicle (1) during operation. A carrier (1) according to any one of claims 1 to 4, characterised in that

6. A carrier (1) according to any one of claims 1 to 5, characterized in that the carrier (1) comprises a rotary encoder (23) connected to at least one of the first and second carrier rolling means (10, 11) and enabling angular position feedback during operation. ）。

7. 7. Carrier (1) according to claim 6, characterized in that the rotary encoder (23) is of the optical encoder type.

8. 8. The vehicle (1) according to claim 6 or 7, characterized in that the rotary encoder (23) is a rotary encoder disk arranged within the outer periphery (9) of the at least one of the first and second vehicle rolling means (10, 11).

9. At least one of the first and second drive means (5, 19) comprises an electric motor (5, 19) comprising a rotor (5) and a stator (19); The vehicle (1) further comprises means (24) for measuring the acceleration of at least one of the first and second vehicle rolling means (10, 11), the means (24) being in signal communication with the stator (19). A carrier (1) according to any one of the preceding claims, characterised in that it is

10. 10. Carrier (1) according to claim 9, characterized in that the means (24) for measuring acceleration comprise at least one of a piezoelectric sensor and an inductive sensor.

11. Each rolling set has at least two wheels (101-104, 111-114); The vehicle (1) further comprises motor control electronics arranged in a volume between two of the wheels of each rolling set (101-104, 111-114) and configured to supply power to the first and second vehicle rolling means (10, 11). A carrier (1) according to any one of claims 1 to 10, characterised in that

12. said first vehicle rolling means (10) comprises four X wheels (101-104) having their direction of rotation in said first direction; The second carrier rolling means (11) comprises four Y wheels (111-114) having a rotation direction in the second direction; Each of the X wheels and each of the Y wheels are drivingly connected to the first drive means (5, 19) and the second drive means (5, 19), respectively. A carrier (1) according to any one of the preceding claims, characterized in that it is

13. The vehicle (1) according to claim 12, characterized in that each of the wheels (101-104, 111-114) has a number of rotor magnets (5) arranged within the inner radial surface of the outer periphery (9) of the wheel and a number of stator field windings (19a) arranged at least partially within the vehicle body (4).

14. Vehicle (1) according to claim 13, characterised in that the stator field winding (19a) follows the outer periphery (9) of the wheels (101-104, 111-114).

15. A vehicle (1) according to any of claims 12 to 14, characterised in that for each wheel (101-104, 111-114), at least a part of said drive means (5, 19) is arranged within the outer periphery (9) of said wheel.

16. A storage system (3) for storing boxes (2), comprising: A box storage structure (15) comprising a plurality of storage rows (8, 8a, 8b) arranged to accommodate vertically stacked storage boxes (2). (15) and A remote control carrier (1) according to any one of claims 1 to 15, which is disposed on the box storage structure (15); A storage system (3), comprising:

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