Method and system for controlling operation of container cargo handling vehicle and drone for automatic storage recovery system

Abstract

To provide a method, a system, and a computer program for controlling and adjusting interaction between a drone and a container cargo handling vehicle operated below and on the top of an automatic storage recovery system.SOLUTION: It is ensured that a drone and a container cargo handling vehicle 200 have minimum or most cost effective waiting time when a storage container 106 is transferred therebetween. Various steps are executed by an operation controller that communicates with a first type of a controller of each container cargo handling vehicle 200 and a second type of a controller of each drone, and timing information is an important factor.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an automatic storage and retrieval system having a grid structure and a shipping system, comprising a port located at a first position in the lower part of the automatic storage and retrieval system. A drone is used to transport storage containers between the port and a second position, typically a picking station. More specifically, the present invention relates to a method, system, and computer program for controlling and coordinating the interaction between a drone and a container handling vehicle, which operate respectively below and at the top of an automatic storage and retrieval system.

Background Art

[0002] FIG. 1 discloses a typical prior art automatic storage and retrieval system 10 having a framework structure 100, in which a container handling vehicle 200, also called a robot, operates the automatic storage and retrieval system 10 when traveling on a rail system 108 at the top of the framework structure 100.

[0003] The framework structure 100 comprises a plurality of vertical members 102 and any plurality of horizontal members 103 that support the plurality of vertical members 102. The members 102, 103 may typically be made of metal, such as aluminum extrusions.

[0004] The framework structure 100 defines a storage grid 104 comprising storage columns 105 arranged in columns, within which storage containers 106, also known as bins, are stacked vertically to form a stack 107. Each storage container 106 may typically hold a plurality of items (not shown).

[0005] The automatic storage and retrieval system 10 includes a rail system 108 for a container handling vehicle 200. The rail system 108 is arranged in a grid pattern across the top of the storage grid 104. The container handling vehicle 200 travels on the rail system 108 and is operated to raise and lower the storage container 106 to and from the storage column 105 and to transport the storage container 106 on the rail system 108. One horizontal range of the grid cells 122 that make up the grid pattern is shown by a thick line in FIG. 1.

[0006] The rail system 108 includes a first set of parallel rails 110 arranged to guide the movement of the container handling vehicle 200 in a first direction X passing across the top of the frame structure 100, and a second set of parallel rails 111 arranged perpendicular to the first set of rails 110 to guide the movement of the container handling vehicle 200 in a second direction Y perpendicular to the first direction X. In this way, the rail system 108 defines grid columns on which the container handling vehicle 200 can move laterally above the storage column 105, that is, within a plane parallel to the horizontal X - Y plane.

[0007] Each container handling vehicle 200 includes a vehicle body and a wheel configuration of eight wheels 201. By means of a first four - wheel set, the container handling vehicle 200 can move laterally in the X direction, and by means of the remaining second four - wheel set, it can move laterally in the Y direction. One or both of the wheel sets of the wheel configuration can be raised and lowered, thereby engaging the first wheel set and / or the second wheel set with the respective rail sets 110, 111, which is defined by a controller that controls the movement and direction of the container handling vehicle 200.

[0008] Each container handling vehicle 200 is provided with a lifting device (not shown) that vertically transports the storage container 106, for example, lifts the storage container 106 from the storage column 105 and lowers the storage container 106 into the storage column 105. The lifting device includes one or more gripping / engagement devices (not shown) adapted to engage the storage container 106. The gripping / engagement device can be lowered from the vehicle 200 by the lifting device to adjust the position of the gripping / engagement device in a third direction Z orthogonal to the first and second directions X, Y.

[0009] When transporting the storage container 106 across the rail system 108, each container handling vehicle 200 is provided with a storage compartment or space (not shown) for receiving and loading the storage container 106. The storage space may include, for example, a cavity disposed centrally within the vehicle body, as described in WO2014 / 090684A1, which is incorporated herein by reference in its entirety.

[0010] Alternatively, the container handling vehicle 200 may have a cantilever structure, as described in NO317366, which is also incorporated herein by reference in its entirety. In the storage grid 104, most of the grid columns are storage columns 105, that is, the grid columns 105 in which the storage containers 106 are stored in a stack 107. However, the storage grid 104 typically has at least one grid column that is not used for storing the storage container 106. Instead, it is used by the container handling vehicle 200 to unload and / or load the storage container 106 so that the storage container 106 can be accessed from outside the storage grid 104 or transported to a second position (not shown) where it can be moved in and out of the storage grid 104. In the art, such a position is typically referred to as a "port", and the grid column in which the port is located may be referred to as a "shipping column" 119. The unloading and loading ports of the container handling vehicle 200 are referred to as the "upper port of the shipping column" 119. The opposite end of the shipping column is referred to as the "lower port of the shipping column".

[0011] The storage grid 104 of FIG. 1 includes two shipping columns 119 and 120. The first shipping column 119 may include, for example, a dedicated unloading port through which a container handling vehicle 200 can unload a storage container 106 and be further conveyed through the shipping column 119 to an access or transfer station (not shown). The second shipping column 120 may include a dedicated loading port through which the container handling vehicle 200 can load the storage container 106 that has been conveyed from an access or transfer station (not shown) through the shipping column 120. The ports of the first and second shipping columns 119, 120 may each include ports suitable for both loading and unloading the storage container 106.

[0012] The second position may typically be a picking or stocking station where items are removed from or positioned within the storage container 106. At the picking or stocking station, the storage container 106 is not normally removed from the automated storage and retrieval system 10, but is returned into the storage grid 104 when accessed. Lower ports are also provided in the shipping columns for moving the storage containers in and out of the storage grid 104. Such lower ports are used, for example, to transfer the storage container 106 directly to another storage facility (e.g., another storage grid), to a transport vehicle (e.g., a train or a freight car), or to a production facility.

[0013] To monitor and control the automated storage and retrieval system 10, the system typically includes a computerized control system (not shown) with a database that tracks the storage containers 106 and keeps track of which bins are being handled at any given time, i.e., which bins are being retrieved or stored. The control system may monitor and control the position of each storage container 106 within the storage grid 104, the contents of each storage container 106, as well as the position and movement of the container handling vehicle 200, thereby enabling the container handling vehicle 200 to unload the desired storage container 106 at the desired location at the desired time without colliding with each other.

[0014] When the storage container 106 stored in the storage grid 104 disclosed in FIG. 1 is accessed, the control system commands one of the container handling vehicles 200 to retrieve the storage container 106 from its current position within the storage grid 104 and convey it to or through the first shipping column 119. This operation involves moving the container handling vehicle 200 to a grid position above the storage column 105 where the target storage container 106 is located, using a lifting device (not shown) of the container handling vehicle to retrieve the storage container 106 from the storage column 105, and conveying the storage container 106 to the first shipping column 119. If the target storage container 106 is located deep within the stack 107, i.e., if one or more other storage containers are located above the target storage container 106, the operation will include temporarily moving the storage containers located above the target storage container 106 before lifting the target storage container 106 out of the storage column 105. This step may be referred to in the art as "digging out" and may be performed using the same container handling vehicle 200 that will later be used to convey the target storage container 106 to the shipping column, or using one or more other cooperating container handling vehicles 200. Alternatively, or in addition, the automated storage retrieval system 10 may have a container handling vehicle 200 that is specifically specialized for the task of temporarily removing the storage container 106 from the storage column 105. Once the target storage container 106 has been removed from the storage column 105, the temporarily removed storage container 106 can be repositioned back within the original storage column 105. However, the removed storage container may alternatively be moved to another storage column 105.

[0015] When the storage container 106 is to be stored within the storage grid 104, one of the container handling vehicles 200 is instructed to load the storage container 106 from the second outbound column 120 and transport it to a grid position above the storage column 105 in which it is to be stored. If there are any storage containers positioned at or above the target position within the storage column stack 107, they are removed and then the container handling vehicle 200 positions the storage container 106 at the desired location. The removed storage container may then be lowered back into the storage column 105 or transferred to another storage column 105.

[0016] A problem associated with the known automated storage and retrieval system 10 is that the area around the loading and unloading ports can become congested with the container handling vehicles 200 that have been instructed to unload or load the storage containers 106. This can be a significant disruption to the operation of the automated storage and retrieval system 10. In a small system, this situation may be alleviated because adding outbound columns to the grid allows the container handling vehicles 200 to be distributed among the multiple ports of the outbound columns, thereby avoiding congestion. However, when ports and columns are added, the infrastructure of the conveyor system typically has to be increased. This requires space, which may not always be available. Also, adding and maintaining the infrastructure of the conveyor system is costly.

[0017] Another problem with the prior art automatic storage and retrieval system 10 is that the separate unloading ports and loading ports of the outbound columns 119, 120 require the container handling vehicle 200 to move to the storage column 105 after unloading to retrieve a new storage container 106. Similarly, the container handling vehicle 200 must be emptied, i.e., when the storage container 106 is sent to the loading port 120 to load the storage container 106, the storage container 106 must be in a state of being empty. This results in inefficiency, as the container handling vehicle 200 moves around on the storage grid 104 without a storage container 106 as its payload, causing an increase in congestion around the ports. In addition, the outbound columns 119, 120 may occupy the space of the storage grid 104 that can be used for other purposes, such as supporting the container handling vehicle 200 passing through the columns 119, 120. to occupy.

[0018] The present invention provides a new method for avoiding the above problems during the handling and transfer of storage containers 106 between the automatic storage and retrieval system.

Summary of the Invention

[0019] The present invention is a method for controlling the operations of a container handling vehicle and a drone so that the total elapsed time or waiting time cost for transferring a storage container between the container handling vehicle and the remotely operated drone is minimized or optimized based on a weight function, wherein the drone operates at a level below an automatic storage and retrieval system having a framework structure defining a storage grid for storing storage containers in grid cells, and the storage containers are stored and retrieved by a container handling vehicle traveling on top of the storage grid.

[0020] The following steps are performed by at least one operation controller communicating with a first type of controller in each container handling vehicle and a second type of controller in each drone.

[0021] When a designated storage container is to be transferred from a storage column and its corresponding grid cell to the drone, By sending instructions to the first type of controller in the assigned container handling vehicle, the storage container is loaded from the grid cell, and the container handling vehicle is assigned and instructed to lower it to the selected port located at the lower end of the specified empty outbound column; Moving the container handling vehicle to the grid cell, loading the storage container, and transporting it to the grid cell of the outbound column with the port; Sending a signal including the selected port at the first position and information on when the storage container will be available at the port to the drone; Based on the response from the drone, assigning and instructing the drone to retrieve the specified storage container; Moving the drone to the port at the first position, loading the storage container, and transporting it to the second position; And / or when the specified storage container should be transferred to the grid cell by the drone for storage in its corresponding storage column, Determining which port at the first position should be used; Sending an instruction to the second type of controller of the drone to transport the storage container from its current position representing the second position to the port at the first position; Moving the drone from the second position to the port at the first position; Sending a signal including information on the port from which the storage container is retrieved to the container handling vehicle; Based on the response from the container handling vehicle, assigning and instructing the container handling vehicle to lift and retrieve the specified storage container from the port at the first position; Lifting the storage container from the port through the outbound column, and moving the container handling vehicle transporting the storage container to the grid cell corresponding to the storage column to which the specified storage container should be transferred.

[0022] Depending on the size of the storage grid, the number of ports for transferring storage containers between the container handling vehicle and the drone may vary. In the case of a smaller system, for example, only two ports, one for lowering the retrieved storage container and one for lifting the storage container to be stored, may be allocated for this purpose. Different configurations are possible and can be customized according to the size of the storage grid and the size of the available area below the storage grid where the drone is operating. It can be customized according to the size of the storage grid and the size of the available area below the storage grid where the drone is operating.

[0023] If there are several ports available for transferring the storage container, the port that best fits for use can be determined. The ports can be grouped together below the outbound column in the allocated area below the storage grid or can be dispersed at different locations below the storage grid.

[0024] In one embodiment, when a specified storage container is to be transferred between the drone and the container handling vehicle between grid cells, the port selected from a series of ports available for transferring the storage container is based on a trade-off between the best matching travel time of the container handling vehicle between the nearest available port and the grid cell between which the storage container is to be transferred, and the position of the nearest available port accessible to the drone.

[0025] The travel times of the available container handling vehicles are calculated. This is based on their current positions, the routes they can take to reach the grid cell where a particular storage container is to be stored or retrieved from, and the time taken to reach the cell where there is an available port.

[0026] The travel times of the available drones are also based on their current positions, the routes they can take to reach the port where a particular storage container is to be transferred between the container handling vehicle and the drone, and the time taken to reach the cell where there is an available port.

[0027] Therefore, the port selected to transfer the storage container is based on a trade-off between the container handling vehicle and the drone that have the best-matching travel time to the port. The goal is to select, by the drone and the container handling vehicle, the port that results in the shortest time used to transfer the specified storage container between the storage grid. In addition to this, an optimal timing is achieved where the waiting at the port during the transfer of the storage container is minimized.

[0028] This means that the container handling vehicle or the drone do not need to wait for each other, and the storage container is transferred through the port. When retrieving the specified storage container, the aspects that contribute to the elapsed time for preparation to be transferred to the drone at the port are the time used to move from its current position to the grid cell where the storage container is stored, the time used for loading, the time used to move to the grid cell where the port is located, and the time used to unload at the port.

[0029] Retrieving the storage container may include digging it out, i.e., first removing other containers on top of it before accessing the container. This operation may be performed by a container handling vehicle other than the one selected to transfer to the port so that the specific storage container is available when the selected container handling vehicle reaches the cell where the storage container is located.

[0030] In one embodiment, when the specified storage container is to be transferred to the grid cell by the drone and the container handling vehicle, the container handling vehicle assigned to retrieve the specified storage container from the port at the first position is currently available and, from the perspective of the drone, has the best-matching travel time from its current position to the port.

[0031] In another embodiment, when a designated storage container is to be retrieved from a grid cell by a container handling vehicle and a drone, the drone assigned to retrieve the designated storage container from the port at the first position is currently available and, from the perspective of the container handling vehicle, has the best-matching travel time from its current position to the port. It has the best-matching travel time from its current position to the port from the perspective of the container handling vehicle.

[0032] The present invention further includes a system that can control the operation of a container handling vehicle traveling on top of a storage grid and a drone operating at a lower level of an automatic storage and retrieval system so that, based on a weight function, the total elapsed time or waiting time cost for transferring a storage container between the container handling vehicle and the remotely operated drone is minimized or optimized.

[0033] The system includes an operation controller that is signal-connected to the controllers of all robots and all drones. In this way, the operation controller always has an overview and control of the positions and availability of the robots and drones. Through the interaction of the controllers, the above-described method can be implemented.

[0034] The present invention further includes a computer program which, when executed by a computer, implements the above-described method of controlling the operation of a drone so that, based on a weight function, the total elapsed time or waiting time cost for transferring a storage container between a container handling vehicle and the remotely operated drone is minimized or optimized, wherein the drone operates at a lower level of an automatic storage and retrieval system having a framework structure defining a storage grid for storing the storage container in a grid cell, and the storage container is stored and retrieved by a container handling vehicle traveling on top of the storage grid.

[0035] An advantage of the present invention is to provide optimal control of a new automatic storage and retrieval system equipped with both a container handling vehicle and a drone. This means that the efficiency of storing and retrieving items in the storage container is improved.

[0036] The following drawings depict exemplary embodiments of the present invention and are provided to facilitate understanding of the present invention.

Brief Description of the Drawings

[0037]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Best Mode for Carrying Out the Invention

[0038] The present invention will now be discussed in more detail with reference to the accompanying drawings. However, it should be understood that the drawings are not intended to limit the subject matter illustrated by the present invention.

[0039] A typical prior art of the automatic storage and retrieval system 10 including the framework structure 100 is described in the background art section. The container handling vehicle rail system 108 enables the container handling vehicle 200 to move horizontally between different grid positions, each grid position being associated with a grid cell 122.

[0040] In FIG. 1, the storage grid 104 is shown with a height of eight grid cells 122. However, it is understood that the storage grid 104 can in principle be of any size. The storage grid 104 can be significantly wider and / or longer than that disclosed in FIG. 1. For example, the storage grid 104 may have a horizontal extent exceeding 700×700 storage columns 105. Also, the storage grid 104 can be significantly deeper than that disclosed in FIG. 1. For example, the storage grid 104 may have a depth, i.e., in the Z direction shown in FIG. 1, exceeding 12 grid cells 122.

[0041] The container vehicle 200 can be of any type known in the art, for example, any of the automated container handling vehicles disclosed in WO2014 / 090684A1, NO317366, or WO2015 / 193278A1. Methods and control systems for controlling the above prior art systems are known.

[0042] The applicant has developed a new solution for operating an automated storage and retrieval system that solves or at least mitigates one or more problems associated with the use of prior art storage and retrieval systems.

[0043] In this system shown in FIG. 2, a dedicated container handling vehicle called a drone 30 operates in the area below the automated storage and retrieval system 10. To efficiently handle the storage container 106, the drone 30 must cooperate with a container handling vehicle 106 that travels on top of the automated storage and retrieval system 10.

[0044] The drone 30 differs from the container handling vehicle 200 in terms of its structural features and the way it handles the storage container 106. The container handling vehicle 200 handles the storage container 106 by lifting and lowering the storage container below the lower part, while the drone 30 dispenses and receives the container 106 above the upper part.

[0045] Figure 2 shows a perspective view of the new automatic storage and retrieval system 10. In addition to the container handling vehicle 200 configured to move on the rail system 108 above the storage column 105, the new system further includes a shipping system 140 with one or more drones 30. The drone 30 is configured to receive and support one or more storage containers 106 for transporting between one or more shipping columns 119, 120 and one or more predetermined positions outside the storage grid 104. The predetermined position may be, for example, a second position or a transport vehicle such as a conveyor line or a truck.

[0046] In the embodiment shown in Figure 2, the drone 30 has a container carrier configuration on its upper surface. In this way, the drone 30 can receive and ship the container 106 when positioned directly below the shipping columns 119, 120. The drone shown in Figure 2 further includes wheels adapted to travel on a track, as well as propulsion means, a controller, communication means, and a power source.

[0047] The new system includes a storage grid 104 and a shipping system 140 located below the storage grid 104. The example of Figure 2 shows a shipping rail system 50. To obtain the largest storage space for the storage containers in the storage and retrieval grid, it may be advantageous to position the shipping rail system 50 such that the extension into the storage grid 104 is minimized. This means that the storage and retrieval grid includes a plurality of storage columns 105 extending from the upper level to the base of the storage grid 104, whereby the entire storage column 105 can be used for storage, obtaining the maximum possible storage capacity.

[0048] The shipping rail system may include a first rail system located within the framework structure of the storage grid 104 and a second rail system located outside the framework structure of the storage grid 104, and the first and second rail systems are connected such that the drone 30 can operate between the rail systems.

[0049] The rails are not essential for the new system to function fully. For example, the drone 30 may travel directly on the floor or hover above the floor. The storage grid 104 in the above new solution is equal to or similar to the storage grid 104 of the prior art described above, that is, it has a rail system 108, a plurality of stacks 107 of storage containers 106, and a plurality of container handling vehicles 200 for lifting and moving the storage containers 106 stacked in the stack 107, and is configured to transfer the storage containers 106 between the upper port and the lower port of each outbound column using the container handling vehicle 200. It is a storage grid 104 including outbound columns 119, 120.

[0050] The outbound system 140 may further include an outbound rail system 50 placed below the outbound ports 150 of one or more outbound columns 119, 120, as illustrated in FIG. 2. The outbound rail system 50 may be constructed in the same or a similar form as the rail system 108 of the container handling vehicle 200.

[0051] The outbound system 140 may further include an interface connectable to a third - party storage, production, and distribution system. The outbound system 140 may also be integrated with a third - party storage, production, and distribution system such that the storage containers 106 are transported between the outbound system 140 and the third - party storage, production, and distribution system. The outbound system 140 may further be connectable to a third - party storage, production, and distribution system such as a production facility, a storage grid, an assembly facility, a receiving or delivery location, etc. The connection may be made using a connectable rail system or a conveyor system including a conveyor used to transport the storage containers 106 between the outbound system 140 and the third - party storage, production, and distribution system.

[0052] The outgoing rail system 50 can be fully or partially integrated into the storage grid 104. However, it is considered advantageous for ensuring efficient operation that the outgoing rail system 50 has a horizontal range covering the outgoing ports 150 at the bottom of at least one of the outgoing columns 119, 120.

[0053] FIG. 2 is a perspective view of an automatic storage and retrieval system having an outgoing rail system 50 extending from a position inside the storage grid 104 to a position outside the storage grid 104. The structure for picking an item and placing it in the storage container 106 at one or more second positions may be arranged anywhere around the portion of the outgoing rail system 50 located outside the storage grid 104. As another way or in addition, a conveyor may be arranged around or near the same periphery of the outgoing rail system 50.

[0054] The new system poses a problem regarding optimal adjustment when transferring the storage container 106 between the container handling vehicle 200 and the drone 30 operating at different levels of the automatic storage and retrieval system 10.

[0055] One object of the present invention is to provide a method for controlling a new automatic storage and retrieval system 10 that increases the availability of the outgoing columns 119, 120 for the container handling vehicle 200 operating on the rail system. This is achieved by a method of controlling and coordinating the interaction between the drone 30 and the container handling vehicle 200 operating respectively below and above the automatic storage and retrieval system.

[0056] When using and controlling the container handling vehicle 200 and the drone 30 to transfer the storage container 106, the present invention provides an automatic storage and retrieval system that is controlled in a more efficient manner than prior art systems, thereby avoiding or at least reducing the congestion of the storage containers 106 around the outgoing columns 119, 120.

[0057] According to the new method, the storage container 106 is transferred between the container handling vehicle (robot) 200 and the drone in a manner that is as time - efficient and / or cost - efficient as possible. The most time - efficient method is to minimize the total elapsed time for transferring the storage container 106 between the container handling vehicle 200 and the drone 30, i.e., each having a minimum waiting time. This is achieved when the container handling vehicle 200 and the drone 30 each have the best batching transfer time when transferring the storage container 106 between them. Ideally, this means that each arrives at the port 150 simultaneously.

[0058] However, the waiting time cost of the container handling vehicle 200 is usually greater than that for the drone 30. The most cost - efficient method is to ensure that the container handling vehicle 200 is always occupied with handling the storage container 106. This may implicitly mean that the drone 30 selected to transfer the storage container 106 between the container handling vehicle 299 has to wait at the port for some time until the container handling vehicle 200 is ready to transfer the storage container 106 at the port 150.

[0059] The minimum or optimal waiting cost can be based on a weight function, where the selected port 150, time, and waiting cost are variables included in the function. The drone 30 moves between a first and a second position in the area below the automated storage and retrieval system 10.

[0060] The first position has a grid structure for storing the storage container 106 in the grid cell 122, and the storage container 106 travels on top of the storage grid 104 and is handled by the container handling vehicle 200 adapted to transfer the storage container 106 via the shipping columns 119, 120, and is defined at a level below the automated storage and retrieval system 10. More specifically, the first position is the position 150 directly below the shipping columns 119, 120.

[0061] The second position is the position where the drone 30 currently is. This may be, for example, a picking or stocking station where an item is taken out of or positioned into the storage container 106. It may also be a temporary position where the drone is located while waiting for instructions regarding which shipping columns 119, 120 to interact with for the shipping or retrieval of the storage container 106.

[0062] The different steps of the method are performed by at least one operation controller 210 that communicates electronically with the first controller 220 of each container handling vehicle 200 and the second controller 230 of each drone 30.

[0063] In one embodiment, the at least one operation controller 210 is a master controller that communicates with the first type of controller 220 within each container handling vehicle 200 and the second type of controller 230 within each drone 30.

[0064] In another embodiment, the at least one operation controller 210 is a master controller signal connected to a sub - controller that communicates with the first type of controller 220 within each container handling vehicle 200 and the second type of controller 230 within each drone 30. In this way, the master controller can delegate the control of the container handling vehicle 200 and the drone 30 to the sub - controller. The master controller may, for example, select the port 150 used to transfer the storage container 106 and an approximate target time for the transfer based on information from the underlying system. Next, the sub - controller can assign and select the container handling vehicle 200 and the drone 30 used to transfer the storage container 106 located at the port 150.

[0065] In one scenario, when a designated storage container 106 is to be transferred from storage to the drone 30, the first step is to determine which storage column 105 and corresponding grid cell 122 the designated storage container 106 is stored in. The operation controller 210 then determines which container handling vehicle 200 should be assigned to the task. The operation controller 210 then commands the selected container handling vehicle 200 to load the storage container 106 from the determined grid cell 122 and lower it to the selected port 150 placed at the lower end of the identified empty storage column 105 and its corresponding grid cell 122. This becomes the first outbound column 119 described above.

[0066] If the designated storage container 106 is located below a stack of other storage containers 106 in the same storage column 105, the other storage containers 106 are first removed by the assigned container handling vehicle 200 or other container handling vehicles 200 assigned to this operation.

[0067] The selected port 150 is typically the port 150 or series of ports 150 allocated to transfer the storage container 106 from a container handling vehicle 200 operating at the top of the storage grid 10 to a drone 30 operating at a lower level below the container handling vehicle 200. This level may correspond to the example shown in Figure 2.

[0068] In another embodiment, the selected port 150 may change according to the current empty outbound column 119. Determining which port 150 is most suitable for current use can be advantageous in larger systems where multiple container handling vehicles 200 and drones 30 operate the same automated storage and retrieval system 10.

[0069] In one embodiment, a port 150 selected to transfer a storage container between a container handling vehicle 200 and a drone 30 is based on a trade-off between the nearest empty grid cell 122 and the corresponding empty outbound column 119 having an outbound port 150, and the grid cell 122 corresponding to the storage column 105 in which the storage container 106 is stored.

[0070] All decisions regarding which container handling vehicle 200 and drone 30 to use to handle a particular storage container 106 are based on timing information. The above trade-off is adjusted so that the waiting time when transferring the storage container 106 between the container handling vehicle 200 and the drone 30 is minimized. Ideally, this means that the drone 30 arrives at the port 150 for loading at approximately the same time that the storage container 106 is unloaded at the port 150 by the container handling vehicle 200.

[0071] In addition to the minimum waiting time at the port 150, another aspect considered is to utilize the outbound column 119 as efficiently as possible. This means that when a storage container is transferred through the outbound column, another storage container can be transferred. Since the operation controller has a complete overview of which containers should be transferred through the port 150 and in what order, the container handling vehicle 200 that handles the storage container 106 is continuously selected and ranked so that a new transfer is carried out when the outbound column 119 becomes empty after transferring a storage container.

[0072] By efficiently utilizing the outbound column 119, the number of outbound columns that do not need to be installed in the storage grid 104 is reduced, thereby providing more storage capacity. When a particular storage container 106 is requested to be retrieved, the time required for retrieval is estimated, and a container handling vehicle 200 available for loading is determined. The time required to retrieve the container 106 is based on its position in the stack of storage containers 106 and the availability of the container handling vehicle 200 for retrieval. If the requested storage container 106 is located below other storage containers 106 in the storage column 105, the other storage containers 106 must be removed first. This affects the time required to retrieve the storage container 106 from its position in the storage column 105.

[0073] When the container handling vehicle 200 retrieves the storage container 106, the time required to move the storage container to the selected cell 122 and lower it to the corresponding port 150 is determined. The total time required to retrieve the storage container 106 from its position in the storage column 105 and discharge it at the port 150 is the input data for selecting which drone 30 to select for loading.

[0074] When a command is sent from the operation controller 210 to the first controller 220 of the assigned container handling vehicle 200, the request is further sent to the second controller 230 of each drone 30, along with information on the selected port 150 where the storage container 106 should be exchanged and the estimated time when the storage container is expected to reach the port 150. Next, the drone 30 available for loading the storage container 106 at the estimated time reports this to the operation controller 210. This may be a drone 30 that is not currently handling a storage container 106 or a drone 30 that is currently returning the storage container to be stored in the automatic storage and retrieval system 10.

[0075] In one embodiment, when a particular storage container 106 is requested and the total time required to discharge it at the port 150 is estimated, timing information regarding the expected arrival time of the storage container 106 at the particular port 150 is provided to the drone.

[0076] In another embodiment, updated timing information regarding the arrival time of the storage container 106 at port 150 is continuously estimated and transmitted to the drone. Since the traffic of the different container handling vehicles 200 traveling on the rail system 108 on the storage grid 104 can be complex and constantly changing, this may provide a more flexible and accurate way to control the drone 30 to provide a minimum waiting time for loading the storage container 106 at port 150.

[0077] Based on the response from the drone 30, the operation controller 210 assigns a specific drone 30 to pick up the designated storage container 106 at the first position at port 150 and transport it to the second position. The second position may be, for example, a picking station as described above. Which drone 30 is assigned to load the storage container 106 is determined according to different factors such as the position of the drone 30 when requested and the work that the drone is currently performing.

[0078] In another scenario, when the designated storage container 106 is to be stored in the storage column 105 by first being transferred to port 150 by the drone 30, the first step is to determine which port 150 the storage container 106 should be transferred to when it is at the first position.

[0079] As described above, the port 150 is usually predefined when setting up the system. In the examples shown in FIGS. 1 and 2 and the corresponding above description, the port 150 in the second outbound column 120 is used to transfer the storage container 106 from the drone 30 to the container handling vehicle 200.

[0080] The operation controller 210 will always have an overall overview and control of the movements and operations of all the container handling vehicles 200, drones 30, and storage containers 106 within the system. Therefore, it is known which drone 30 should transfer a specific storage container 106 to port 150.

[0081] The next step of the method is to send a command from the operation controller 210 to the second controller 230 of the drone 30 to transfer the storage container 106 from its current position representing the second position to the selected port 150 at the first position.

[0082] The last step is to assign the container handling vehicle 200 to collect the designated storage container 106 from the port 150 at the first position. Next, it is transferred to the determined grid cell 122.

[0083] One particular scenario provides an efficient way of using the drone 30. In this scenario, the drone 30 is first commanded to transfer the storage container 106 from the second position to the first position at the port 150 of the corresponding second outbound column 120. Next, the drone 30 is commanded to immediately load another storage container 106 from the port 150 of the corresponding first outbound column 119.

[0084] In one embodiment of the present invention, the operation controller 210 may control the speeds of the drone 30 and the container handling vehicle 200 based on the speed at which a human and / or robotic arm picks items from the storage container 106 and / or places items therein at the picking station. In this way, different picking stations can be operated at different speeds. This ensures smooth handling of the storage container 106 and avoids congestion of the drone 30 at a particular picking station.

[0085] The following example describes a scenario in which the container handling vehicle 200 performs the replacement of the storage container 106. When the storage container 106 is to be retrieved from the storage of the automatic storage and retrieval system 10, the container handling vehicle 200 performs the container replacement by returning one storage container 106 to the automatic storage and retrieval system 10 each time the storage container 106 is shipped out to the drone 30. This involves the operation controller 210 transmitting a signal to the container handling vehicle 200 that it must prepare to receive another storage container 106 immediately after the storage container 106 is shipped out. This may involve the container handling vehicle 200 not lifting its lifting device all the way to the top of the cell 122, but only lifting it enough so that the storage container 106 being transferred to the drone 30 is emptied. Next, a second drone 30 that transports the storage container 106 to be returned to storage aligns beside the drone 30 that receives the storage container 106 and moves to the position immediately after the first drone 30 leaves. Next, the same container handling vehicle 200 can quickly load the returned storage container 106 and return it to the automatic storage and retrieval system 10 for placement.

[0086] In another scenario, when the storage container 106 is to be returned to the storage grid 104 without replacing the storage container 106, the operation controller 210 sends a signal to the controller of the selected container handling vehicle 200 that is not currently handling a load, indicating that the drone 30 needs to move to a specific grid cell 122, or a grid cell 122 selected from among the options of grid cell 122, where the container handling vehicle 200 is located. Next, the controller of the selected container handling vehicle 200 instructs it to move to the given grid cell 122, or a grid cell 122 among the options of grid cell 122 that it can reach most efficiently. Next, the port 150 corresponding to the selected grid cell 122 is communicated by the operation controller 210 to the controller of the drone 30 for the storage container Return it to the storage grid 104, and the drone 30 starts moving towards the selected port 150. When the container handling vehicle 200 moves to the selected grid cell 122, it lowers its lifting device directly above where the drone is operating, that is, to the port 150, so that as soon as the drone 30 reaches the selected port 150, it is ready to load the storage container 106.

[0087] As can be understood from the above considerations, the operation controller 210 controls and adjusts the operations of the container handling vehicle 200 and the drone 30. Ideally, their waiting times when transferring the storage container 106 between the container handling vehicle 200 and the drone 30 are minimized. To achieve this, the operations of the container handling vehicle 200 and the drone 30 are adjusted. This is based on timing information.

[0088] There are different operations that contribute to the elapsed time of the container handling vehicle 200 and the drone 30 when loading the storage container 106. When the storage container 106 is requested to be retrieved from the storage column 105, the first operation is to determine which container handling vehicle 200 is going to load, and then determine the time it takes for the selected container handling vehicle 200 to move from its current position to the cell 122 corresponding to the storage column 105 where the requested storage container 106 is stored. Which container handling vehicle 200 is selected depends on the position of the container handling vehicles 200 on the grid and the different routes they can take to reach the cell 122 above the requested storage container 106.

[0089] If the route is a straight line along the rails, the time to reach the destination cell 122 is dominated by the vehicle's acceleration, maximum speed, and deceleration. If a zigzag route needs to be taken, in addition to these factors, the time required to raise and lower the second wheel set and move vertically also contributes to the decision of which container handling vehicle 200 is optimal for retrieving the requested storage container 106.

[0090] The next operation may first involve removing other storage containers 106 placed on top of the requested storage container 106. This excavation operation may contribute a significant amount of time depending on at which level below the topmost storage container 106 the requested storage container 106 is located. The excavation operation may be performed by a container handling vehicle 200 other than the one selected to carry the storage container 106 to port 150. In this way, when the selected container handling vehicle 200 reaches its position, the requested storage container 106 may be ready to be loaded.

[0091] The next operation is to transport the storage container 106 from the cell 122 corresponding to the storage column 105 from which the storage container 106 was retrieved to the selected cell 122 of the selected storage column 105 having the port 150. The last step contributing to the total elapsed time from when the storage container 106 is requested until it becomes available at the port 150 is to lower the storage container 106 into the port 150.

[0092] The different time estimates are based on the empirical data and operating speed of the selected container handling vehicle 106. The estimated total time for the requested storage container 106 to become available at the port 150 is the input value when the operation controller starts transmitting information about the selected port 150 in the first position to the drone 30, and the time when the requested storage container is ready to be loaded at the port 150. As described above, the estimated total time can be continuously updated and transmitted to the drone 30.

[0093] FIG. 3 shows an example of the steps performed when retrieving the bin / storage container 106. In this example, bin #341 is to be retrieved from the storage grid 104. The first step 300 is to determine the position (x, y, z), for example (2, 5, 4), of the requested bin #341. This means that it is stored in the grid cell (2, 5) at level 4, i.e., three other storage containers 106 are stacked on top of it. This position is transmitted as a signal to the robot / container handling vehicle 200 in step 310.

[0094] The robots currently available for handling bins report this, and as shown in step 320, the operation controller receives a signal from robot 200 that is ready to load bin #341.

[0095] In step 330, robot 200 with the shortest travel time to grid cell (x,y), in this case cell (2,5), is selected. This is based on calculations, but since other robots are constantly moving on the grid, the available paths (not blocked) are very complex. Once a particular robot is selected, it moves to grid cell (x,y), i.e., (2,5) in this example, and is instructed to load the bin (see step 340). Since the bin is stored below three other bins, the other bins must be removed first before bin #341 can be accessed. This operation can be performed by the selected robot itself or by other robots. These may be dedicated to that task. Ideally, when the selected robot reaches the destination cell, bin #341 has been dug out.

[0096] The next step 350 is to select which port 150 to use to transfer bin #341 to drone 50. The number and location of the available ports 150, as well as the corresponding grid cells 122, are determined according to the structural characteristics of the storage grid 104. Larger systems are typically built with a greater number of ports 150 than smaller systems. Although only one port 150 can be used, at least two ports 150 provide a more efficient solution where one can be used to transfer bin 106 from robot 200 to drone 30 and another can be used to transfer the bin from drone 30 to robot 200 at the same time.

[0097] In larger systems, several ports 150 can be grouped together and / or dispersed so that different positions within the area covered by the storage grid 106 are covered.

[0098] The port 150 selected to transfer the bin is signaled to the drone 30 as the bin reaches the port 150 (see step 360). The drone 30 currently available for handling bin #341 reports this, and as shown in step 370, the operation controller receives a signal from the drone 30 that is ready to load the bin.

[0099] The selected drone 30 is assigned to load bin #341 as shown in 380. This is typically the drone 30 that has the best matching travel time to a particular port 150. It may also be the drone with the shortest travel time to the assigned port 150. Next, this drone 30 moves to the selected port 150, loads bin #341, and is instructed to move it to another location (see step 390). The port is at the first location and the other location is the second location, for example, the conveyor belt at the picking station.

[0100] In one embodiment, the robot 200 stays in the grid cell 122 where the port 150 is located, holds its lifting device at the port, and is instructed to return another bin 106 to the storage grid 106 (see step 395). This saves time when the robot 200 is instructed to store another bin 106 in the storage grid 104 because the lifting device of the robot 200 is already at the port 150.

[0101] FIG. 4 shows an example of the steps performed when storing a bin / storage container 106. In this example, bin #292 is to be stored in the storage grid 104. The port 150 may be located, for example, in grid cell (7,1).

[0102] The port 150 used to transfer the bin 106 to the storage grid 104 is selected (see step 410). Which port 150 to use to transfer bin #292 to the robot 200 depends on different factors such as the number of available ports 150 and the positions of the ports 150, as in the previous example described above.

[0103] Once the port 150 to be used is determined, the drone 150 is instructed to move to the selected port 150 (see step 420). Information about the selected port 150 and the time when bin #292 will be available at the port is sent to the robot 200 (see step 430).

[0104] The robots currently available for handling the bins report this, and as shown in step 440, the operation controller receives a signal from the robot 200 that is ready to load bin #292.

[0105] The robot 200 having the best matching travel time to the grid cell (7,1) and the time when its lifting device will be available at the port 150 is selected and assigned to retrieve the bin in view of the drone 150 discharging bin #292 (see step 450). This is based on calculations, but since other robots are constantly moving on the grid, the available paths (unblocked) are very complex. The selected robot 200 moves to the grid cell (7,1), lowers its lifting device to the port 150, loads bin #292, and is instructed to store it at the position (x,y,x).

[0106] In one embodiment, the drone 30 is instructed to stay at the port 150 and retrieve another bin 106 from the storage grid 106 (see step 465). This saves time, for example, when another robot 150 has already retrieved a bin and lowered it to a nearby port 150.

[0107] FIG. 5 shows a system that can control the operation of a container handling vehicle traveling on top of a storage grid 104 and a drone operating at a level below the automated storage and retrieval system 10 so that the total elapsed time or waiting time cost for transferring the storage container 106 between the container handling vehicle 200 and the remotely operated drone 30 is minimized or optimized based on a weight function.

[0108] The system includes an operation controller 210 that is signal-connected to all robot controllers and all drone controllers. A communication path is provided between at least one operation controller 210, a first type of controller 220 within each container handling vehicle / robot 200, and a second type of controller 230 within each drone 30. In this way, the operation controller 210 always has an overview and control of the positions and availability of the robots and drones. The interaction of the controllers enables the implementation of the method described above.

Claims

1. A method of controlling the operation of the container handling vehicle (200) and the drone (30) such that the total elapsed time or waiting time cost for transferring the storage container (106) between the container handling vehicle and the remotely operated drone is minimized or optimized based on a weight function, wherein the drone (30) operates at a level below an automatic storage and retrieval system (10) having a framework structure (100) defining a storage grid (104) for storing the storage container (106) in a grid cell (122), and the storage container (106) is stored and retrieved by a container handling vehicle (200) traveling on top of the storage grid (104), and by at least one operation controller (210) communicating with a first type of controller (220) in each container handling vehicle (200) and a second type of controller (230) in each drone (30), when a specified storage container (106) is to be transferred from a storage column (105) and a corresponding grid cell (122) to the drone (30), sending a command to the first type of controller (220) of the assigned container handling vehicle (200) to load the storage container (106) from the grid cell (122) and assign and command the container handling vehicle to lower it to a selected port (150) located at the lower end of a specified empty shipping column (119, 120); moving the container handling vehicle (200) to the grid cell (122), loading the storage container (106), and transporting it to the grid cell (122) of the shipping column (119, 120) where the port (150) is located; sending a signal including the selected port (150) at the first position and information on when the storage container (106) will be available at the port (150) to the drone (30); assigning and commanding the drone (30) to retrieve the specified storage container (106) based on a response from the drone (30); moving the drone (30) to the port (150) at the first position, loading the storage container (106), and transporting it to a second position And / or, when a designated storage container (106) is to be transferred by a drone (30) to a grid cell (122) for storage in a corresponding storage column (105), determining which port (150) at the first position is to be used; sending an instruction to the second type of controller (230) of the drone (30) to convey the storage container (106) from the current position representing the second position to the port (150) at the first position; moving the drone (30) from the second position to the port (150) at the first position; sending a signal including information on the port (150) from which the storage container is to be retrieved to the container handling vehicle (200); allocating and instructing a container handling vehicle (200) to lift and retrieve the designated storage container (106) from the port (150) at the first position based on a response from the container handling vehicle (200); lifting the storage container (106) from the port (150) through the shipping columns (119, 120) and moving the container handling vehicle (200) that conveys the storage container (106) to a grid cell (122) corresponding to the storage column (105) to which the designated storage container (106) is to be transferred, the method being implemented. Claim 2 When a designated storage container (106) is to be transferred between the drone (30) and the container handling vehicle (20 0) and the grid cell (122), the port (150) selected from a series of ports (150) available for transferring the storage container (106) is based on a trade-off between the best matching travel time of the container handling vehicle (200) between the nearest available port (150) and the grid cell (122) between which the storage container (106) is to be transferred and the travel time to the port (150) of the empty drone (30). The method according to claim 1. Claim 3 The method according to claim 1, wherein when the designated storage container (106) is to be transferred to the grid cell (122) by the drone (30) and the container handling vehicle (200), the container handling vehicle (200) assigned to retrieve the designated storage container (106) from the port (150) at the first position is available and has the best matching travel time to the port, which is the shortest time for the lifting device to lower from the current position to the port (150).

4. The method according to claim 1, wherein when the designated storage container (106) is to be retrieved from the grid cell (122) by the container handling vehicle (200) and the drone (30), the drone (30) assigned to retrieve the designated storage container (106) from the port (150) at the first position is available and has the best matching travel time from the current position to the port (150).

5. A system for controlling the operations of the container handling vehicle and the drone such that the total elapsed time or waiting time cost for transferring the storage container (106) between the container handling vehicle (200) and the remotely operated drone (30) is minimized or optimized based on a weight function, wherein the drone (30) operates at a level below an automated storage and retrieval system (10) having a framework structure (100) defining a storage grid (104) for storing the storage container (106) in a grid cell (122), the storage container (106) being stored and retrieved by a container handling vehicle (200) traveling on top of the storage grid (104), and at least one operation controller (210) communicates with a first type of controller (220) within each container handling vehicle (200) and a second type of controller (230) within each drone (30), the controller being adapted to implement the method according to claims 1 to 4.

6. A computer program that, when executed by a computer, controls the operations of the container handling vehicle and the drone when transferring the storage container (106) between the container handling vehicle (200) and the remotely operated drone (30), implementing the method according to claims 1 to 4.

Images