Automated storage tower with carousel

Abstract

To provide a storage grid and an automated storage and retrieval system for storing and retrieving a container to / from such a storage grid.SOLUTION: There are provided a storage tower (400), an automated storage and retrieval system and a method for using them. The storage tower (400) includes a vertically extending support structure having a vertical axis and a plurality of horizontally oriented container supports (402) arranged along the vertical axis of the support structure and distributed at vertical intervals. Each container support (402) is rotationally connected to the support structure and is configured to support at least one storage container. Each container support (402) presents at least one opening, the at least one opening having a size at least as large as the maximum horizontal cross section of a storage container (106) to be stored.SELECTED DRAWING: Figure 5a

Description

[Technical Field]

[0001] The present invention relates to a storage grid and an automated storage and retrieval system for storing and retrieving containers from / to such a storage grid. The present invention also relates to a method for storing and retrieving containers within such a storage grid and for accessing deeper located containers in a more time efficient manner. [Background technology]

[0002] FIG. 1 discloses a typical prior art automated storage and retrieval system 1 with a framework structure 100, and FIGS. 2 and 3 disclose two different prior art container handling vehicles 201, 301 suitable for operating on such a system 1.

[0003] The skeleton structure 100 comprises upright members 102, horizontal members 103, and a storage volume comprising storage columns 105 arranged in rows between the upright members 102 and the horizontal members 103. In these storage columns 105, storage containers 106, also known as receptacles, are stacked on top of each other to form stacks 107. The members 102, 103 may typically consist of metal, for example extruded aluminum profiles.

[0004] The framework structure 100 of the automated storage and retrieval system 1 includes a rail system 108 arranged across the top of the framework structure 100, on which a plurality of container handling vehicles 201, 301 are operated to lift storage containers 106 from, lower storage containers 106 into, and transport storage containers 106 up the storage columns 105. The rail system 108 includes a first set of parallel rails 110 arranged to guide movement of the container handling vehicles 201, 301 in a first direction X across the top of the framework structure 100, and a second set of parallel rails 111 arranged perpendicular to the first set of rails 110 for guiding movement of the container handling vehicles 201, 301 in a second direction Y that is perpendicular to the first direction X. Containers 106 stored in columns 105 are accessed by container handling vehicles through access openings 112 in rail system 108. Container handling vehicles 201, 301 can move laterally above storage columns 105, i.e., in a plane that is parallel to the horizontal XY plane.

[0005] The uprights 102 of the skeletal structure 100 may be used to guide the storage containers during lifting and lowering of the containers out of and into the columns 105. The stacks 107 of containers 106 are typically freestanding.

[0006] Each prior art container handling vehicle 201, 301 comprises a body 201a, 301a and first and second sets of wheels 201b, 301b, 201c, 301c, respectively, which allow lateral movement of the container handling vehicle 201, 301 in the X and Y directions. In Figures 2 and 3, two wheels in each set are fully visible. The first set of wheels 201b, 301b are arranged to engage two adjacent rails of the first set of rails 110, and the second set of wheels 201c, 301c are arranged to engage two adjacent rails of the second set of rails 111. At least one of the sets of wheels 201b, 301b, 201c, 301c can be raised and lowered so that the first set of wheels 201b, 301b and / or the second set of wheels 201c, 301c can be engaged with a respective set of rails 110, 111 at any one time.

[0007] Each prior art container handling vehicle 201, 301 also includes a lifting device (not shown) for vertical transportation of the storage containers 106, e.g., for lifting the storage containers 106 from the storage columns 105 and lowering the storage containers 106 into the storage columns 105. The lifting device includes one or more gripping / engaging devices adapted to engage with the storage containers 106, such that the position of the gripping / engaging device relative to the vehicle 201, 301 can be adjusted in a third direction Z that is orthogonal to the first direction X and the second direction Y, and the gripping / engaging device can be lowered from the vehicle 201, 301. A portion of the gripping device of the container handling vehicle 301 is shown in FIG. 3 and designated with reference numeral 304. The gripping device of the container handling device 201 is located within the vehicle body 301a of FIG. 2.

[0008] As before, and for purposes of this application, Z=1 identifies the top layer of storage containers, i.e., the layer immediately below rail system 108, Z=2 identifies the second layer below rail system 108, Z=3 identifies the third layer, and so on. In the exemplary prior art disclosed in FIG. 1, Z=8 identifies the lowest bottom layer of storage containers. Similarly, X=1...n and Y=1...n identify the position of each storage column 105 in the horizontal plane. Consequently, using the Cartesian coordinate system X, Y, Z shown in FIG. 1 as an example, the storage container identified as 106' in FIG. 1 may be said to occupy storage location X=10, Y=2, Z=3. Container handling vehicles 201, 301 may be said to travel in layer Z=0, and each storage column 105 may be identified by its X and Y coordinates.

[0009] The storage volume of the skeleton structure 100 is often referred to as a grid 104, and the possible storage locations within this grid are referred to as storage cells. Each storage column may be identified by its position in the X and Y directions, while each storage cell may be identified by its container number in the X, Y, and Z directions.

[0010] Each prior art container handling vehicle 201, 301 includes a storage compartment or space for receiving and housing the storage containers 106 as they are transported across the rail system 108. The storage space may include a centrally arranged cavity within the vehicle body 201 a, as shown in FIG. 2 and as described, for example, in WO 2015 / 193278 A1 (Patent Document 1), the contents of which are incorporated herein by reference.

[0011] 3 shows an alternative configuration of a container handling vehicle 301 with a cantilever structure. Such a vehicle is described in detail, for example, in No. 317366, the contents of which are also incorporated herein by reference.

[0012] 2 may have a footprint covering an area with dimensions in the X and Y directions generally equal to the lateral extent of the storage column 105, as described, for example, in WO 2015 / 193278 A1, the contents of which are incorporated herein by reference. As used herein, the term "lateral" may mean "horizontal."

[0013] Alternatively, the central hollow container handling vehicle 101 may have a footprint that is larger than the lateral area defined by the storage columns 105, as disclosed, for example, in WO2014 / 090684A1 (Patent Document 2).

[0014] Rail system 108 typically includes rails with grooves into which vehicle wheels extend. Alternatively, the rails may include upwardly protruding elements, and the vehicle wheels may include flanges to prevent derailment. These grooves and upwardly protruding elements are collectively known as tracks. Each rail may include one track, or each rail may include two parallel tracks.

[0015] WO2018146304 (Patent Document 3), the contents of which are incorporated herein by reference, illustrates a typical configuration of a rail system 108 comprising rails and parallel tracks in both the X and Y directions.

[0016] In the skeleton structure 100, the majority of the columns 105 are storage columns 105, i.e., columns 105 where storage containers 106 are stored in stacks 107. However, some columns 105 may have other purposes. In FIG. 1 , columns 119 and 120 are such special-purpose columns used by container handling vehicles 201, 301 to unload and / or load storage containers 106 so that they can be accessed from outside the skeleton structure 100 or transported to an access station (not shown) where they can be transferred out of or into the skeleton structure 100. Within the art, such locations are typically referred to as "ports," and the columns in which the ports are located may be referred to as "port columns" 119, 120. Transport to the access station may be in any direction, be horizontal, diagonal, and / or vertical. For example, storage containers 106 may be installed in random or dedicated columns 105 within the framework structure 100, then loaded by any container handling vehicle and transported to port columns 119, 120 for further transport to an access station. Note that the term "diagonal" refers to the transport of storage containers 106 having a general transport orientation somewhere between horizontal and vertical.

[0017] In FIG. 1, the first port column 119 may be, for example, a dedicated loading port column where container handling vehicles 201, 301 may unload storage containers 106 to be transported to an access or transfer station, and the second port column 120 may be a dedicated loading port column where container handling vehicles 201, 301 may load storage containers 106 being transported from an access or transfer station.

[0018] An access station may typically be a picking station or stockpiling station where product items are removed from or placed into storage containers 106. At a picking or stockpiling station, the storage containers 106 are typically not removed from the automated storage and retrieval system 1, but once accessed, are placed back into the backbone structure 100. Ports can also be used to transfer storage containers to another storage facility (e.g., to another backbone structure or to another automated storage and retrieval system), to a transport vehicle (e.g., a train or lorry), or to a production facility.

[0019] A conveyor system comprising conveyors is typically employed to transport storage containers between the port columns 119, 120 and the access stations.

[0020] If the port columns 119, 120 and the access stations are located on different levels, the conveyor system may include a lifting device with a vertical component for vertically transporting the storage containers 106 between the port columns 119, 120 and the access stations.

[0021] The conveyor system may be arranged to transport storage containers 106 between different skeletal structures, for example as described in WO2014 / 075937A1 (Patent Document 4), the contents of which are incorporated herein by reference.

[0022] 1 is to be accessed, one of the container handling vehicles 201, 301 is commanded to retrieve the target storage container 106 from its location and transport it to the unloading port column 119. This operation involves moving the container handling vehicle 201, 301 to a location above the storage column 105 in which the target storage container 106 is located, using a lifting device (not shown) of the container handling vehicle 201, 301 to retrieve the storage container 106 from the storage column 105, and transporting the storage container 106 to the unloading port column 119. If the target storage container 106 is located deep within the stack 107, i.e., one or more other storage containers 106 are positioned above the target storage container 106, the operation also involves temporarily moving the above-positioned storage container prior to raising the target storage container 106 from the storage column 105. This step, sometimes referred to within the art as "digging," may be performed using the same container handling vehicle used to subsequently transport the target storage container to unloading port column 119, or using one or more other cooperating container handling vehicles. Alternatively, or in addition, automated storage and retrieval system 1 may have a container handling vehicle specifically dedicated to the task of temporarily removing storage containers from storage column 105. Once target storage container 106 is removed from storage column 105, the temporarily removed storage container can be repositioned in the original storage column 105. However, the removed storage container may alternatively be relocated to another storage column.

[0023] When a storage container 106 is to be stored in one of the columns 105, one of the container handling vehicles 201, 301 is commanded to load the storage container 106 from the load port column 120 and transport it to a location above the storage column 105 where it is to be stored. After any storage container located at or above the target location in the storage column stack 107 is removed, the container handling vehicle 201, 301 positions the storage container 106 in the desired location. The removed storage container may then be lowered back into the storage column 105 or relocated to another storage column.

[0024] To monitor and control the automated storage and retrieval system 1, for example, to monitor and control the locations of the individual storage containers 106 within the skeletal structure 100, the contents of each storage container 106, and the movements of the container handling vehicles 201, 301 so that the desired storage containers 106 can be delivered to the desired locations at the desired times without the container handling vehicles 201, 301 colliding with each other, the automated storage and retrieval system 1 typically includes a control system 500, which is typically computerized and typically includes a database for tracking the storage containers 106.

[0025] Figure 4 shows an example of a product item 80 stored within a storage container 106. The storage container 106 shown in Figure 4 has a height Hf, a width Wf, and a length Lf. The storage container 106 has a horizontal cross section Af.

[0026] For systems containing multiple containers in each stack, the "digging" described above can prove both time- and space-consuming when the target container is located deep within the grid. For example, if the target container has location Z=5, the vehicle must lift four non-target containers and place them in other locations, often on the grid (Z=0), before the target container can be reached. Before being reinstalled back into the grid, the non-target containers can force other robots to choose non-optimized paths to perform their individual operations.

[0027] It is therefore an object of the present invention to provide a storage tower, and a storage and retrieval system using such a storage tower, that may provide a more time-efficient method of storage and retrieval compared to prior art systems. [Prior art documents] [Patent documents]

[0028] [Patent Document 1] International Publication No. 2015 / 193278 [Patent Document 2] International Publication No. 2014 / 090684 [Patent Document 3] International Publication No. 2018 / 146304 [Patent Document 4] International Publication No. 2014 / 075937 Summary of the Invention [Means for solving the problem]

[0029] The invention is set out in the independent claims, while the dependent claims describe certain optional features of the invention.

[0030] In particular, the present invention relates to a storage tower for storing storage containers, the storage tower comprising a vertically extending support structure having a vertical axis and m horizontally oriented container supports, where m is a positive integer equal to or greater than 2.

[0031] The container supports may be arranged along a vertical axis of the support structure and supported by a container support skeleton, and the storage supports may be distributed at vertical intervals to provide different levels at which the storage containers may be stored, with each container support being rotatably connected to the support structure and configured to support at least one storage container.

[0032] Each of the l tiers of container supports arranged above the ml remaining tiers of container supports each presents at least one opening, the at least one opening having a size that is at least the maximum horizontal cross-section of a storage container to be stored, where l is a positive integer from 1 to m-1.

[0033] The l container supports can be independently rotated about a vertical axis such that at least one opening on each level of the l container supports can be vertically aligned with at least one opening on another level of the l container supports by individual rotation of the container supports.

[0034] Preferably, all of the container supports in the storage tower are independently rotatable about a vertical axis such that at least one opening in each level of the container supports is vertically alignable with at least one opening in another level of the container supports by individual rotation of the container supports.

[0035] Thus, a storage container is achieved in which a remotely operated vehicle can load the storage container at least to level l+1 without digging, thus saving time.

[0036] Thus, a storage container is achieved that can provide for more time-efficient delivery of product items to customers or other recipients of the items stored within the storage container.

[0037] Thus, a storage tower is achieved that can provide high throughput of product items, such as product items for sale or other products in high demand.

[0038] The horizontal container support framework may have a repeating geometric shape, in particular, l container supports.

[0039] The horizontal container supports can be seen to provide a set of rotatable storage shelves for storage containers whose contents can be easily accessed through aligning openings in the upper container supports with target storage containers below.

[0040] The container support may be a plate, e.g., one continuous plate or several plates connected to form the container support. In other words, the container support may provide a continuous surface for placing the storage container thereon. Alternatively, the container support may have a frame structure, i.e., no internal structure or material between the frame members of the frame structure. Furthermore, the container support may be a combination of the two. The container supports in a storage tower may also be a mixture of the two.

[0041] At least one opening presented by each container support may be a separate opening. The opening need not be within the actual container support. For example, the container support may not extend to the area of ​​the opening. If a container support has two or more openings, the openings may be fused together to form a continuous opening. The container support may include a plurality of openings distributed in an arc on the container support such that the openings are circumferentially offset at equal or approximately equal first radial distances from the vertical axis of the support structure.

[0042] At least one opening and container space of the same container support may be distributed along the same arc.

[0043] The distribution of the at least one opening and container space of each container support is preferably similar for each container support, so that the container space of any container support will be able to perfectly align with the opening of any of the other container supports when they are coaxially arranged.

[0044] The storage tower may include m container support skeletons arranged along a vertical axis of the support structure and distributed at vertical intervals, where m is a positive integer greater than or equal to 2. Each of the container support skeletons is configured to support at least one container support.

[0045] The container skeletons may be arranged without spaces between adjacent container skeletons, for example, where m-1 of the container skeletons rest on top of one below. Alternatively, the container skeletons may be spaced apart.

[0046] The storage tower may include a drive mechanism configured to rotate the at least one container support about a vertical axis of the support structure.

[0047] The drive mechanism may be, for example, a swivel drive, a gear drive, a belt drive, a chain drive, an electromagnetic drive such as a stepper motor.

[0048] The drive mechanism may be arranged on the support structure, container support, or container support skeleton, for example.

[0049] Typically, all container supports on a tower will be rotatable, however the lowest container support may be stationary if all of the container supports above are rotatable and a remotely operated vehicle can be vertically aligned above all potential target storage containers supported on the lowest container support.

[0050] The container support may be at least indirectly rotationally connected to the support structure, for example via a container support skeleton, which may be connected to the support structure in a non-rotational manner.

[0051] Each of the m container supports may include a plurality of first container spaces, the plurality of first container spaces being distributed in an arc on the container support such that the plurality of first container spaces are circumferentially offset at equal or approximately equal first radial distances from a vertical axis of the support structure.

[0052] Each container support may comprise, for example, five first container spaces.

[0053] The first container spaces may be arranged radially symmetrically, however, equal distances between the container spaces are not required.

[0054] The container space may be configured to store storage containers arranged with their lateral directions extending radially relative to the vertical axis of the support structure. In this manner, storage containers to be stored or retrieved may be aligned with one or more grid openings in a grid arranged above the storage tower. Alternatively, the container space may be configured to store storage containers arranged with their longitudinal directions extending radially relative to the vertical axis of the support structure. Furthermore, the container space may be configured to store storage containers arranged with any angular displacement relative to the orientations described above.

[0055] Each of the container supports may further comprise a plurality of second container spaces, the plurality of second container spaces being distributed in an arc on the at least one horizontally oriented container support such that the plurality of second container spaces are circumferentially offset from the vertical axis at equal or approximately equal second radial distances, the second radial distance being greater than the first radial distance. The second radial distance is greater than the first radial distance by at least the width of the container to be stored. A container support may typically comprise seven second container spaces.

[0056] Each of the container supports may further include a plurality of third container spaces, the plurality of third container spaces being distributed in an arc on the at least one horizontally oriented container support such that the plurality of third container spaces are circumferentially offset from the vertical axis by equal or approximately equal third radial distances, the third radial distance being greater than the first and second radial distances. The third radial distance is greater than the second radial distance by at least the length of the containers to be stored. A container support may typically include 11 third container spaces.

[0057] Each container support may have a toroidal horizontal cross section.

[0058] The support structure may be a central pole or a peripheral housing, or a combination of a central pole and a peripheral housing. The housing may be a cage structure.

[0059] At least one of the container supports may include a plurality of sensor devices for sensing the presence of a storage container, and the sensor devices may be distributed across the plurality of container spaces.

[0060] Sensors arranged on the container support or container support framework may be in communication with the control system.

[0061] The sensor device may be selected from the group consisting of a piezoelectric sensor, a weight sensor, a magnetic sensor (which would require the storage container to be made of a magnetic material or to be equipped with a magnet device), a visual sensor, an optical sensor, a motion sensor, an electrical contact, and / or an inductive sensor.

[0062] At least one of the container supports may include a sensor device for sensing rotation of the container support relative to the support structure.

[0063] Each container support skeleton may comprise a plurality of container supports, which may be coaxially arranged and rotatable relative to one another, in which case the first, second and third container spaces of the same container support skeleton may be distributed across the first, second and third container supports, respectively.

[0064] An advantage of this configuration is that two remotely operated vehicles can simultaneously load two separate target storage containers from the same storage tower without interrupting each other. When a first remotely operated vehicle is loading a first storage container from a given container support, a second remotely operated vehicle can load a second or third storage container from any container support in the same storage tower, including the same container support as the first remotely operated vehicle is loading.

[0065] The plurality of first container spaces of the at least one container support skeleton may be distributed over a plurality of container supports, for example when each container support is generally sector-shaped.

[0066] Each of the container support frameworks may further comprise a stationary portion connected to the support structure in a non-rotating manner. The stationary portion may comprise a rotation device, e.g., a wheel, a bearing, a swivel, a roller. At least one container support may be rotationally coupled to the stationary portion.

[0067] It should be understood that the term "coupled to" also encompasses "resting on" and "supported by."

[0068] It should be understood that the term "connected" also encompasses "indirectly connected," so that if a container support is connected to a container support structure, which in turn is connected to a support structure, i.e., the container support is connected to the support structure via the container support structure, then the container support is considered to be connected to the support structure.

[0069] The rotation device may form part of the drive mechanism.

[0070] The stationary portion may form an arm extending horizontally radially from the vertical axis of the support structure. The rotation device may be arranged on the arm, for example at the distal end of the arm. The rotation device arranged on the arm may be powered to rotate the associated container support, thus forming a drive mechanism.

[0071] Each horizontally extending arm may include a plurality of rotation devices configured to support individual container supports and enable rotation of the individual container supports relative to one another.

[0072] The horizontally extending arms may be provided in sets of different lengths, each set configured to support a respective coaxially arranged container support, in which case first, second and third container supports of the same container support framework may be supported by the first, second and third sets of arms, respectively.

[0073] The container support may include a guide post for guiding the storage container into a fixed position in the container space. The storage container may preferably include a guide recess configured to cooperate with the guide post.

[0074] The guide posts will also prevent the storage containers from shifting on the container support when the container support is rotated, i.e., ensure that the storage containers maintain their position during storage.

[0075] Each container support may include a vertical guide plate arranged at least partially around the periphery of each of the at least one opening, and the vertical guide plate may be configured such that storage containers raised or lowered into the respective openings are aligned in a horizontal plane.

[0076] The storage tower may further comprise a transport mechanism arranged above the top container support framework or top container support at a first vertical offset, the first vertical offset being at least the maximum height of the storage containers to be stored.

[0077] Instead of a vehicle with wheels moving on a rail system, the transportation system may include a crane that can move in the X and Y directions across the storage tower (not exactly in those directions, but diagonally in a combination of those directions). For example, the crane may be movable in a first direction on a sliding bar extending across the width of the storage tower. Movement in the second direction may be achieved by sliding the sliding bar along two fixed bars extending in the second direction on either side of the storage tower. Other arrangements and numbers of bars are encompassed herein as long as they can be used to achieve the same movement of the overhead crane. The crane may be a container handling vehicle with a cantilever structure supported on two parallel sliding bars.

[0078] Thus, a storage tower is achieved that can operate despite not being at the same height. The transport mechanism is less prone to derailment than vehicles that move on wheels. The storage tower can therefore be suitable for operation at sea, for example on board a ship.

[0079] The storage tower may alternatively include a rail system arranged above the top container support framework or upper container support.

[0080] The rail system may be arranged above the top container support framework or top container support at a first vertical offset, the first vertical offset being at least the maximum height of the storage containers to be stored.

[0081] The top container support framework or support may be arranged below the lower edge of the upper adjacent rail system at a distance corresponding to a height equal to or greater than the maximum height of the stack of several storage containers. In this way, one portion of a storage tower may partially correspond to a prior art storage grid in that storage containers may be positioned on top of each other to form a stack and that a remotely operated vehicle may need to excavate to reach a target storage container. At the same time, another portion of the same storage tower may include one or more container supports on which storage containers are not stacked so that excavation is not required.

[0082] The rail system may provide access to target openings in a storage tower and adjacent storage towers and / or storage grids without having to cover the entire horizontal extent of the storage tower.

[0083] The present invention also relates to an automated storage and retrieval system configured to store a plurality of storage containers.

[0084] The automated storage and retrieval system may include the storage tower described above.

[0085] Additionally, the automated storage and retrieval system may include a plurality of storage containers supported on a plurality of container supports.

[0086] Additionally, the automated storage and retrieval system may include a remotely operated vehicle configured to move laterally over at least a portion of the plurality of container supports. The remotely operated vehicle may include a lifting device configured to grasp and vertically raise and lower the storage container.

[0087] Additionally, the automated storage and retrieval system may include a control system configured to wirelessly monitor and control the movement of the remotely operated vehicles.

[0088] The remotely operated vehicle can be a storage container vehicle or a crane.

[0089] Thus, an automated storage and retrieval system is achieved in which remotely operated vehicles can load storage containers without the need for digging.

[0090] Thus, an automated storage and retrieval system is achieved that can provide more time-efficient delivery of product items to customers or other recipients of items stored within storage containers.

[0091] Thus, an automated storage and retrieval system is achieved that can provide high throughput of product items, such as product items for sale or other products in high demand.

[0092] Automated storage and retrieval systems a plurality of vertical storage columns for stacking storage containers on top of each other; Rail system and and a storage grid comprising: a plurality of container handling vehicles operable on a rail system, the rail system being arranged above the plurality of storage columns; the storage containers stored in the storage columns are accessible by container handling vehicles through grid openings in the rail system; The rail system may include a cantilevered portion with a horizontal extent equal to the difference between the horizontal extent of the rail system and the horizontal extent of the plurality of storage columns.

[0093] One or more of the storage towers may be arranged, at least in part, below a cantilevered portion of the rail system and positioned such that the l container supports can be independently rotated about a vertical axis, whereby at least one opening of each of the l container supports is vertically alignable with at least one opening of another of the l container supports upon rotation of the container support.

[0094] Alternatively, automated storage and retrieval systems can a plurality of vertical storage columns for stacking storage containers on top of each other; Transport mechanism and the remotely operated vehicle is a crane movable along a sliding bar arranged parallel to a first direction, the sliding bar having two opposite ends movable along two fixed bars arranged parallel to a second direction; and a transport mechanism arranged above the plurality of storage columns, the transport mechanism comprising a cantilever portion with a horizontal extent equal to the difference between the horizontal extent of the transport mechanism and the horizontal extent of the plurality of storage columns.

[0095] One or more of the storage towers may be arranged at least partially below the cantilever portion of the traveling crane system.

[0096] Thus, a storage and retrieval system is achieved that combines the prior art storage grid with the storage tower of the present invention, i.e., a combination of a high extension tower and a low extension grid in which product items can be arranged according to their turnover rate.

[0097] Thus, a storage and retrieval system is achieved that combines storage capacity with time-efficient delivery of product items to customers, where, for example, orders can be loaded from a lower extension grid with high storage capacity before being intermediately stored (buffered) in a higher extension grid with time-efficient delivery of product items to customers, and then efficiently delivered to customers upon their arrival.

[0098] The high extension storage tower is configured for a high frequency of storage containers entering and exiting the storage tower. Storage containers will typically be stored in the high extension storage tower for a shorter period of time compared to the low extension storage grid. The high extension storage tower is particularly suitable for high-demand products. The high extension storage tower provides quick access and is therefore suitable for time-critical storage. The high extension storage tower is less space-efficient than the low extension storage grid.

[0099] The lower extension storage grid is more space efficient compared to the higher extension storage tower. Storage containers will typically be stored in the lower extension grid for longer periods compared to the higher extension storage tower. The lower extension storage grid has slower access compared to the higher extension storage tower and is therefore more suitable for less urgent storage.

[0100] Thus, the high extension storage tower and the low extension storage grid complement each other.

[0101] The automated storage and retrieval system may further include a rail system arranged above the top container support skeleton or top container support at a first vertical offset that is at least the maximum height of the storage containers to be stored.

[0102] The automated storage and retrieval system may alternatively include a transport mechanism arranged above the top container support framework or top container support of the storage tower at a first vertical offset, the first vertical offset being at least the maximum height of the storage containers to be stored.

[0103] At least one of the container support framework or the container support may be arranged below the lower edge of the upper adjacent rail system at a distance corresponding to a height equal to or greater than the maximum height of the stack of several storage containers.

[0104] The present invention also relates to a method for storing and retrieving storage containers from an automated storage and retrieval system, which may be as described above.

[0105] Each of the container supports may include a plurality of first container spaces, the plurality of first container spaces being distributed on the at least one horizontally oriented container support such that the plurality of first container spaces are circumferentially offset at equal or approximately equal first radial distances from the vertical axis.

[0106] The method includes the following steps. Moving a remotely operated vehicle or crane to a position where its lifting device can be vertically aligned with a target storage container positioned above one of the first container spaces or to a position where its lifting device can be vertically aligned with one or more aligned openings of the container support. If necessary, rotating the container support on which the target storage container is supported to position the target storage container in vertical alignment below the location of the remotely operated vehicle or crane. If necessary, and if the container support on which the target storage container is supported is not the uppermost container support, rotating the upper container support, or each of the upper container supports, to a circumferential position where the lifting device has direct vertical access to the target storage container through at least one opening. · Grasping and lifting the target storage container by using a lifting device. Moving the remotely operated vehicle with the target storage container horizontally to a different location.

[0107] Preferably, the container supports may have default positions within the storage tower in which at least one opening of each of the l container supports is vertically aligned. Furthermore, if a rail system is used, the default positions of these aligned openings of the l container supports may preferably be vertically aligned with the grid openings of the rail system. Alternatively, if a transport mechanism is used, the default positions of these aligned openings of the l container supports may preferably be vertically alignable with the lifting device of the crane and have the same horizontal orientation.

[0108] Thus, a method for loading storage containers with remotely operated vehicles is achieved that does not involve the need for digging.

[0109] Thus, a method is achieved that provides for more time-efficient delivery of product items to customers or other recipients of items stored within storage containers.

[0110] Thus, a method for providing high throughput of product items, such as product items for sale or other products in high demand, is achieved.

[0111] When each of the container supports includes multiple second container spaces, and possibly also a third container space, two remotely operated vehicles may simultaneously load a target storage container from the same container support. Alternatively, two remotely operated vehicles may simultaneously store two storage containers in the same container support. As a further alternative, one remotely operated vehicle may retrieve a target storage container from the same container support where another remotely operated vehicle is simultaneously storing a storage container.

[0112] If the remotely operated vehicle or crane is transporting a storage container to be stored within the automated storage and retrieval system either before or after retrieval of the target storage container, the method may include the following steps. Moving the remotely operated vehicle or crane to a position where its lifting device can be vertically aligned with an empty container space, for example to one of the first container spaces, or to a position where its lifting device can be vertically aligned with one or more aligned openings of the container support. If necessary, rotating the container supports of the empty container space to position the empty container space in vertical alignment below the location of the remotely operated vehicle or crane. If the container support of the empty container space is not the uppermost container support, rotating the upper container support, or each of the upper container supports, to a circumferential position in which the lifting device has direct vertical access to the empty container space through at least one opening. Lowering the delivered storage container into position over the empty container space by use of a lifting device.

[0113] Where the automated storage and retrieval system comprises a storage grid containing target storage containers, the method may include the following steps. · Loading the target storage container from the storage grid, for example, as described in the Technical Background section. Storing the target storage container in a storage tower according to the method described above. Retrieving the storage container from the storage tower according to a method for storing and retrieving storage containers.

[0114] The automated storage and retrieval system described above can be used to deliver items arranged in storage containers stored in storage towers directly to end users.

[0115] The present invention also relates to a method for disposing a storage tower in an automated storage and retrieval system. The storage tower and the automated storage and retrieval system may be according to the above description.

[0116] The automated storage and retrieval system may include: Storage grid. · A vehicle movement system with a horizontal extent greater than the storage grid.

[0117] The method includes the following steps. Assembling at least a portion of a storage tower, as described above, beneath the cantilever portion of the vehicle movement system.

[0118] Thus, a storage tower is achieved that can be retrofitted into existing storage and retrieval systems.

[0119] The vehicle movement system may comprise a rail system, and the method may therefore further comprise the following steps: Aligning the storage tower and the rail system so that at least one opening in the first container support skeleton and each of the m-1 top container support skeletons are vertically alignable below a grid opening in a portion of the rail system that extends beyond the storage grid.

[0120] The cantilevered portion of the rail system need not extend the entire horizontal extent of the storage tower, but may, for example, only extend far enough to reach a target opening in the storage tower.

[0121] Due to the configuration of the container supports, the vertical pillars cannot be positioned inside the storage tower, which means that there will be larger spans between the vertical pillars of the storage tower and therefore higher loads on each vertical pillar compared to the uprights of prior art storage grids.

[0122] When present, the rail system must extend over and support its weight over a larger area than with conventional storage grids, where each grid space is supported at the corners by upright members.

[0123] To withstand the increased loads, the vertical pillars and / or rail systems may need to be reinforced compared to prior art uprights and rail systems.

[0124] A remotely operated vehicle approaching a storage tower to load a target storage container typically brings another storage container to be stored into the storage and retrieval system. Before the remotely operated vehicle can load the target storage container, a vehicle-held storage container is advantageously placed into an empty container space within the same storage tower. This is a process typically referred to as an exchange process. Such an exchange process can occur within storage towers and automated storage and retrieval systems as described above.

[0125] By having fewer storage containers, the more container space is available in the storage system, so there will always be at least one empty container space. Empty container space will also be dynamically generated as remotely operated vehicles load storage containers from within the storage tower. If there is no empty container space in the storage system, the remotely operated vehicle must avoid either bringing in another storage container from, for example, a port column or placing a storage container held on top of a storage tower. Both alternatives suffer from drawbacks in terms of time efficiency.

[0126] The empty container (into which the storage container is to be placed) and the target storage container are preferably horizontally closest to the same target opening. In this way, the remotely operated vehicle does not need to move between two operations during the same exchange process. Even more preferably, in addition to being available through the same target opening, the empty container space and the target storage container can be located on the same container support. In this way, the remotely operated vehicle can have minimal movement of its lifting device between two operations of the exchange process. Therefore, the exchange process time will not be extended due to the opposing displacement of the lifting device and the container support of the target storage container.

[0127] After the remotely operated vehicle positions the previously held storage container within the empty container space, the remotely operated vehicle must retract the lifting device. Retracting the lifting device allows the container supports on which the previously held storage containers are positioned to rotate, i.e., return to their predetermined default orientation. The default position of the container supports is typically where at least one opening of each container support is vertically aligned. For time-efficient operation, the remotely operated vehicle should not retract, i.e., raise, the lifting device higher than strictly necessary. If the target storage container is positioned deeper within the storage tower than the location of the previously held storage container, the lifting device only needs to be raised and clear the container support on which the previously held storage container was positioned. If the target storage container is positioned higher within the storage tower than the location of the previously held storage container, the lifting device only needs to be raised and clear the container support on which the target storage container is positioned to be rotated. However, the lifting device does not need to be raised to any higher location. Endless retraction of the lifting device to the remotely operated vehicle is therefore not required unless the target storage container or empty container space is located within the uppermost container support. For time-efficient operation, the container support of the target storage container and the container support of the previously held storage container can be rotated simultaneously.

[0128] After the target storage container is raised above the container support, the container support can be rotated back to its initial position. The present invention provides, for example, the following items. (Item 1) A storage tower (400) for storing storage containers (106), the storage tower (400) comprising: Vertical axis (A v a vertically extending support structure (450) having a m horizontally oriented container supports (402) arranged along the vertical axis of the support structure (450) and supported by a container support skeleton (401), the container supports (402) being distributed at vertical intervals (ΔdV) to provide different levels at which storage containers (106) may be stored, m being a positive integer of 2 or greater, each container support (420) being rotationally connected to the support structure (450) and configured to support at least one storage container (106); Each of the levels of the l container supports (402a-l) arranged above the remaining levels of the l container supports (402) presents at least one opening (403), the at least one opening (403) being at least as large as the maximum horizontal cross section (A) of the storage container (106) to be stored. f ), where l is a positive integer between 1 and m-1; The l container supports (402a-l) are arranged along the vertical axis (A) such that at least one opening (403) of each story of the l container supports (402a-l) can be vertically aligned with at least one opening of another story of the l container supports (402a-l) by individual rotation of the container supports (402a-l). v ) and a storage tower (400) that can be independently rotated around the storage tower (400). (Item 2) The storage tower (400) is v Item 1. The storage tower (400) of item 1, comprising a drive mechanism (700) configured to rotate the at least one container support (402) relative to a drive mechanism (700). (Item 3) Each of the m container support portions (402a to n) includes a plurality of first container spaces (104a), and the plurality of first container spaces (104a) are arranged such that the plurality of first container spaces (104a) are aligned along the vertical axis (A v10. The storage tower (400) of claim 1, wherein the containers are distributed in an arc on the container support (402) so as to be circumferentially offset with a first radial distance (r1) that is equal or approximately equal from the first radial distance (r2) of the container support (402). (Item 4) Each of the container supports (402) further includes a plurality of second container spaces (104b), and the plurality of second container spaces (104b) are arranged such that the plurality of second container spaces (104b) are aligned along the vertical axis (A v 4. The storage tower (400) according to claim 3, wherein the containers are distributed in an arc on the at least one horizontally oriented container support (402) so as to be circumferentially offset by a second radial distance (r2) that is equal to or approximately equal to the first radial distance (r1) from the first radial distance (r1), the second radial distance (r2) being greater than the first radial distance (r1). (Item 5) Item 10. The storage tower (400) of any preceding item, wherein each container support (402) has a toroidal horizontal cross section. (Item 6) 10. The storage tower (400) of any one of the preceding items, wherein the support structure (450) is a central pole or a peripheral housing, or a combination of a central pole and a peripheral housing. (Item 7) The storage tower (400) according to any one of the preceding items, wherein each container support framework (401 a-m) comprises a plurality of container supports (402), the plurality of container supports (402) being arranged coaxially and rotatable relative to one another. (Item 8) The storage tower (400) according to any one of items 3 to 7, wherein the plurality of first container spaces (104a) of at least one container support framework (401) are distributed on a plurality of container supports (402). (Item 9) 10. The storage tower (400) of claim 1, wherein each of the container support frameworks (401 a-m) further comprises a stationary portion connected to the support structure (450) in a non-rotating manner, the stationary portion comprising a rotation device (406), and the at least one horizontally oriented container support (402) is rotationally coupled to the stationary portion. (Item 10) 10. The storage tower (400) according to claim 9, wherein the rotation device (406) forms part of the drive mechanism (700). (Item 11) The stationary portion is aligned with the vertical axis (A v 11. The storage tower (400) according to item 9 or 10, wherein the storage tower (400) forms an arm (405) extending horizontally in a radial direction from the storage tower (400), and the rotation device (406) is arranged at a distal end of the arm (405). (Item 12) Item 12. The storage tower (400) according to item 11, wherein each horizontally extending arm (405) comprises a plurality of rotation devices (406), the plurality of rotation devices (406) being configured to support individual container supports (402) and enable rotation of the individual container supports (402) relative to one another. (Item 13) Item 12. The storage tower (400) of item 11, wherein the horizontally extending arms are provided in sets of different lengths, each set configured to support a respective coaxially arranged container support (402). (Item 14) The storage tower (400) according to any one of the preceding items, wherein the container support (402) is provided with a guide post (407) for guiding the storage container (106) to a fixed position above the container space (104). (Item 15) each container support (402) comprises a vertical guide plate (409) arranged at least partially around the periphery of each of said at least one opening (403); 10. The storage tower (400) of claim 1, wherein the vertical guide plate (409) is configured so that storage containers (106) raised or lowered into the individual openings (403) are aligned in the horizontal plane. (Item 16) The storage tower (400) has a first vertical offset (V r1 ) above the top container support framework (401a) or the top container support (402), and r1 ) is at least the maximum height of the storage containers (106) to be stored. (Item 17) The storage tower (400) according to any one of the preceding items, further comprising a rail system (408) arranged above the top container support framework (401 a) or upper container support (402 a). (Item 18) The rail system (408) has a first vertical offset (V r1 ) above the top container support framework (401a) or the top container support (402a), and the first vertical offset (V r1 18. The storage tower (400) according to item 17, wherein the height of the storage container (106) is at least the maximum height of the storage container (106) to be stored. (Item 19) 19. The storage tower (400) according to item 17 or 18, wherein the uppermost container support framework (401 a) or the uppermost container support (402 a) is arranged below the lower edge of the upper adjacent rail system (408) at a distance corresponding to a height equal to or greater than the maximum height of a stack (107) of several storage containers (106). (Item 20) An automated storage and retrieval system (1) configured to store a plurality of storage containers (106), comprising: One or more storage towers (400) according to any one of items 1 to 16; a plurality of storage containers (106) supported on the plurality of container supports (402); a remotely operated vehicle (201; 301; 602) configured to move laterally above at least a portion of the plurality of container supports (402), the remotely operated vehicle (201; 301; 602) comprising a lifting device (304), the lifting device (304) configured to grasp and vertically lift a storage container (106); a control system (500) configured to wirelessly monitor and control the movement of said remotely operated vehicle (201; 301); An automated storage and retrieval system (1). (Item 21) The storage grid (100) further comprises: a plurality of vertical storage columns (105) for stacking storage containers (106) on top of one another; Rail system (108) and a plurality of container handling vehicles (201; 301) can be operated on the rail system (108), the rail system (108) being arranged above the plurality of storage columns (105); the storage containers (106) stored in the storage columns (105) are accessible by the container handling vehicles (201; 301) through grid openings (115) in the rail system (108); the rail system (108) comprises a cantilever section (CP) with a horizontal extent equal to the difference between the horizontal extent of the rail system (108) and the horizontal extent of the plurality of storage columns (105); Item 21. The automated storage and retrieval system (1) according to item 20, wherein one or more of the storage towers (400) are at least partially arranged below the cantilever portion (CP) of the rail system (108) and positioned such that the l container supports (402a-l) can be independently rotated about the vertical axis, whereby at least one opening (403) of each of the l container supports (402a-l) is vertically alignable with at least one opening of another of the l container supports (402a-l) by rotation of the container support (402a-l). (Item 22) The system (1) further comprises a storage grid (100), the storage grid (100) comprising: a plurality of vertical storage columns (105) for stacking storage containers (106) on top of one another; Transport mechanism and the remotely operated vehicle is a crane (602) movable along a sliding bar (603) arranged parallel to a first direction (X), the sliding bar (603) having two ends movable along two fixed bars (604) arranged parallel to a second direction (Y); the transport mechanism is arranged above the plurality of storage columns (105), the transport mechanism comprising a cantilever portion (CP) with a horizontal extent equal to the difference between the horizontal extent of the transport mechanism and the horizontal extent of the plurality of storage columns (105); Item 21. The automated storage and retrieval system (1) according to item 20, wherein one or more of the storage towers (400) are at least partially arranged below a cantilever portion (CP) of the traveling crane system (108). (Item 23) The storage tower (400) has a first vertical offset (V r1 ), the rail system (408) is arranged above the top container support framework (401a) or the top container support (402a), and the first vertical offset (V r121. The automated storage and retrieval system (1) according to item 20, wherein the height of the storage container (106) to be stored is at least the maximum height of the storage container (106). (Item 24) Item 24. The automated storage and retrieval system (1) according to item 23, wherein at least one of the container support frameworks (401) is arranged below the lower edge of the upper adjacent rail system (408) at a distance corresponding to a height equal to or greater than the maximum height of a stack (107) of several storage containers (106). (Item 25) A method for storing and retrieving a storage container (106) from an automated storage and retrieval system (1) according to any one of items 20 to 24, comprising: Each of the container support parts (402a-n) includes a plurality of first container spaces (104a), and the plurality of first container spaces (104a) are arranged such that the plurality of first container spaces (104a) are aligned along the vertical axis (A v ) distributed on said at least one horizontally oriented container support (402) so as to be circumferentially offset with a first radial distance (r1) that is equal or approximately equal from said first radial distance (r1) of said at least one horizontally oriented container support (402); The method comprises: moving the remotely operated vehicle (201; 301) or the crane (602) to a position where its lifting device (304) can be vertically aligned with a target storage container (106') positioned above one of the first container spaces (104a), or to a position where its lifting device can be vertically aligned with one or more aligned openings (403) of the container support (402); If necessary, rotating the container support (402) on which the target storage container (106') is supported to position the target storage container (106') in vertical alignment below the location of the remotely operated vehicle (201; 301) or the crane (602); if necessary, and if the container support (402) on which the target storage container (106') is supported is not the uppermost container support (402a), rotating the, or each, upper container support (402) to a circumferential position where the lifting device (340) has direct vertical access to the target storage container (106) through the at least one opening (403); grasping and lifting the target storage container (106') by using the lifting device (304); moving the remotely operated vehicle (201; 301; 602) with the target storage container (106') horizontally to a different location; A method comprising: (Item 26) The remotely operated vehicle (201; 301) or the crane (602) transports a storage container (106) to be stored in the automated storage and retrieval system (1) either before or after retrieval of the target storage container (106'), and the method comprises: moving the remotely operated vehicle (201; 301) or the crane (602) to a position where its lifting device (304) can be vertically aligned with an empty container space (106'') or to a position where its lifting device can be vertically aligned with one or more aligned openings (403) of the container support (402); if necessary, rotating the container support (402) of said empty container space (106'') to position said empty container space (106'') in vertical alignment below the position of said remotely operated vehicle (201; 301) or said crane (602); if the container support (402) of the empty container space (106'') is not the uppermost container support (402a), rotating the, or each, upper container support (402) to a circumferential position where the lifting device (340) has direct vertical access to the empty container space (106'') through the at least one opening (403); lowering the transported storage container (106) to a position above the empty container space (106'') by using the lifting device (304); Item 26. The method according to Item 25, comprising: (Item 27) The automated storage and retrieval system (1) comprises a storage grid (100) containing target storage containers (106'), and the method comprises: stow the target storage container (106') from the storage grid (100); storing the target storage container (106') in the storage tower (400) according to item 26; retrieving the storage container (106') from the storage tower (400) in accordance with item 25; 27. The method according to Item 26, comprising: (Item 28) Use of the automated storage and retrieval system (1) according to any one of items 20 to 24 for directly delivering items arranged in the storage containers stored in the storage tower (400) to an end user. [Brief explanation of the drawings]

[0129] The following drawings are included to facilitate an understanding of the invention: The drawings illustrate embodiments of the invention, which will now be described by way of example only.

[0130] [Figure 1] FIG. 1 is a perspective view of the skeletal structure of a prior art automated storage and retrieval system.

[0131] [Figure 2] FIG. 2 is a perspective view of a prior art container handling vehicle having a centrally arranged cavity for transporting storage containers therein.

[0132] [Figure 3] FIG. 3 is a perspective view of a prior art container handling vehicle having a cantilever for transporting storage containers underneath.

[0133] [Figure 4] FIG. 4 is a perspective view of a storage container and a product item stored within the storage container.

[0134] [Figure 5a] FIG. 5a is a top view of a storage system in which the rail system is arranged above the storage tower with the openings of each container support aligned vertically below grid openings in the rail system.

[0135] [Figure 5b] FIG. 5b is a top view of the storage system of FIG. 5a, with one container support rotated relative to the other container support.

[0136] [Figure 5c] FIG. 5c is a top view of the storage system of FIGS. 5a-b in which one of the container supports is rotated relative to the other container support so that the storage container is vertically aligned with the grid openings and the openings of the aligned container support.

[0137] [Figure 6] FIG. 6 is a perspective view of the storage system of FIGS. 5a-c, in which a remotely operated vehicle having a lifting device and movable on a rail system is positioned in vertical alignment above the grid openings.

[0138] [Figure 7]FIG. 7 is a top view of a storage system in which the container supports are configured with container spaces and / or openings alignable beneath two different grid openings.

[0139] [Figure 8] FIG. 8 is a top view of a storage system in which the container supports are configured with container spaces and / or openings alignable beneath three different grid openings.

[0140] [Figure 9] FIG. 9 is a side view of a storage system according to one embodiment of the invention in which the storage grid and storage tower are positioned side-by-side and below the rail system.

[0141] [Figure 10] FIG. 10 is a side view of the storage system of FIG. 9 with all container supports except the bottom and top removed from the storage tower.

[0142] [Figure 11] FIG. 11 is a perspective view of a detail of the storage system of FIG. 9 with all but the two lowest container supports removed from the storage tower.

[0143] [Figure 12] FIG. 12 is a side view of a detail of the storage system of FIG. 9 showing the container support framework and drive mechanism of the storage tower.

[0144] [Figure 13] FIG. 13 is a perspective view of another embodiment of a storage system according to the present invention in which a storage grid and multiple storage towers are positioned side-by-side and below a rail system.

[0145] [Figure 14] FIG. 14 is a side view of the storage system of FIG. 9, in which the storage tower has two empty container spaces.

[0146] [Figure 15] FIG. 15 is a side view of the storage system of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0147] Detailed Description of the Invention In the following, embodiments of the present invention will be discussed in more detail with reference to the accompanying drawings, in which it should be understood, however, that the drawings are not intended to limit the invention to the subject matter depicted in the drawings.

[0148] The skeleton structure 100 of the automated storage and retrieval system 1 is constructed as the prior art skeleton structure 100 described above in connection with Figures 1 to 3, i.e., by several upright members 102 and several horizontal members 103 supported by the upright members 102, and further, the skeleton structure 100 comprises a first upper rail system 108 in the X and Y directions.

[0149] Skeleton structure 100 further comprises a storage compartment in the form of a storage column 105 provided between members 102 and 103, with storage containers 106 stackable in stacks 107 within storage column 105.

[0150] Skeleton structure 100 can be of any size. In particular, it should be understood that skeletal structure can be significantly wider and / or longer and / or deeper than that disclosed in Figure 1. For example, skeletal structure 100 may have a horizontal extent of greater than 700 x 700 columns and a storage depth of greater than 12 containers.

[0151] An embodiment of an automated storage and retrieval system according to the present invention will now be discussed in more detail with reference to Figures 5a-15.

[0152] In the foregoing description, various aspects of the delivery vehicle and automated storage and retrieval system according to the present invention have been described with reference to illustrative embodiments. For purposes of explanation, specific numbers, systems, and configurations have been set forth to provide a thorough understanding of the system and its operation. 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, that are apparent to those skilled in the art to which the disclosed subject matter pertains are deemed to be within the scope of the present invention.

[0153] 5-6 and 9-15, the storage and retrieval system 1 of the present invention comprises a remotely operated vehicle 301 operating on a rail system 408 comprising a first set of parallel rails 410 arranged to guide movement of the remotely operated vehicle 301 in a first direction X across a storage grid 400, and a second set of parallel rails 411 arranged perpendicular to the first set of rails 410 for guiding movement of the remotely operated vehicle 301 in a second direction Y that is perpendicular to the first direction X. Storage containers 106 stored within the storage tower 400 are accessed by the remotely operated vehicle 301 through grid openings 415 in the rail system 408. Each grid opening 415 of the rail system 408 is enclosed by a grid cell 422. The rail system 408 is arranged in a horizontal plane P rs (See FIG. 7).

[0154] As best seen in FIG. 9, the storage container 106 is r1 The containers are stored on a plurality of container supports 402 distributed in the Z direction below the rail system 408 with a vertical offset indicated by ΔdV (i.e., the offset between the lower edge of the rail system 408 and the lower edge for the first container support 402a directly below the rail system 408) and a vertical offset indicated by ΔdV (i.e., the average offset between the lower edges of adjacent deeper placed container supports 402b-m).

[0155] Although "m," the 13th letter of the alphabet, is used to identify the lowest container support in the embodiment of Figure 9, representing 13 tiers of container supports, other numbers of tiers of container supports may be present in the storage and retrieval system. Thus, m is not limited to the number 13, but can be equal to any integer equal to 2 or greater.

[0156] Vertical offset V r1 and ΔdV may be selected to provide a height equal to or greater than the maximum height of one storage container 106 or stack 107 of several storage containers 106. As an example, a first container support 402a may be adapted to store a stack 107 of storage containers 106, while lower-mounted container supports 402b-m (or some of them) may be adapted to store single (unstacked) storage containers 106. As a further example, some or all container supports 402 of a tower 400 may be adapted to store a stack 107 of several storage containers 106. Different container supports 402 of the same storage tower 400 may be configured to store stacks 107 of unequal numbers of storage containers 106. The vertical space (i.e., available height) required for one or several container supports 402 of a storage tower 400 to be adapted to store a stack 107 of several storage containers 106 can be obtained by reducing the total number of container supports 402 compared to a configuration of a storage tower 400 in which all container supports 402 are adapted to store a single (unstacked) storage container 106.

[0157] Figures 5a-c show the vertical axis A v1 shows a top view of a storage tower 400 comprising a vertically extending support structure 450 having a plurality of horizontally oriented container supports 402a-m arranged along the vertical axis of the support structure 450 and distributed at a vertical spacing ΔdV, as described above. Each container support 420 is rotationally connected to the support structure 450 and configured to support at least one storage container 106.

[0158] The remaining l container supports 402a to l arranged above the remaining ml container supports 402 each present at least one opening 403, and the at least one opening 403 has a width at least equal to the maximum horizontal cross section A of the storage container 106 to be stored. f The size is:

[0159] Like the number "m," the integer "integer" is not limited to any particular integer, but may include any integer less than "m."

[0160] The l container supports 402a-l are oriented along the vertical axis A such that at least one opening 403 of each of the m container supports 402a-m is vertically alignable with at least one opening of the other m container supports 402a-m by individual rotation of the container supports 402a-m. v can be independently rotated around.

[0161] Storage tower 400 may include a plurality of container support frameworks 410 a - m , each configured to support at least one container support 402 .

[0162] Each container support 402 is configured such that the plurality of first container spaces 104a are aligned with the vertical axis A of the support structure 450. v 11, the container support 402 may include a plurality of first container spaces 104a distributed in an arc on the container support 402 such that the first container spaces 104a are circumferentially offset at equal or approximately equal first radial distances r1 from the container support 402. In the embodiment of FIG. 11, the container support 402 includes six first container spaces 104a and one opening 403.

[0163] The container spaces 104 of the container support 402 are spaced apart by a width that is perpendicular to the vertical axis A of the support structure 450. v The storage tower 400 may be configured to store storage containers 106 arranged in a radially extending manner relative to the rail system 408. In this manner, a storage container 106 to be stored or retrieved may be vertically aligned with one or more grid openings 415 of the rail system 408 arranged above the storage tower 400 (the length and width of the grid openings 415 being aligned with the length and width of the storage containers 106). When one of the first container spaces 104a is vertically aligned with a grid opening 415, the other first container spaces 104a can also be vertically aligned with the same grid opening 415 by rotating the container support 402.

[0164] FIG. 7 shows the container support 402, in which the plurality of first container spaces 104a are aligned with the vertical axis A of the support structure 450. v 10 shows that the container support 402 may have a plurality of first container spaces 104a distributed in an arc on the container support 402 so as to be circumferentially offset at equal or nearly equal first radial distances r1 from the container support 402. The container support 402 of this example has five first container spaces 104a and one first opening 403a.

[0165] FIG. 7 also shows that the container support 402 is configured to support the plurality of second container spaces 104b along the vertical axis A v 10B, the container support portion 402 may include a plurality of second container spaces 104b distributed in an arc so as to be circumferentially offset from the first container space 104b by an equal or nearly equal second radial distance r2, the second radial distance r2 being greater than the first radial distance r1. The second radial distance r2 is greater than the first radial distance r1 by at least the width of the storage container 106 to be stored. The container support portion 402 of this embodiment may include seven second container spaces 104b and a second opening 403b.

[0166] 8 shows the container support 402 of FIG. 7, in which the plurality of third container spaces 104c are aligned along the vertical axis A v 10 shows that the storage container 106 may include a plurality of third container spaces 104c distributed in an arc on at least one horizontally oriented container support 402 so as to be circumferentially offset from the first container space 104c by an equal or approximately equal third radial distance r3, where the third radial distance r3 is greater than the first and second radial distances r1, r2. The third radial distance r3 is greater than the second radial distance r2 by at least the length of the storage containers 106 to be stored. The container support 402 of this example includes eleven third container spaces 104c and a third opening 403c.

[0167] The number of first, second, and third container spaces 104c may vary depending on, for example, the number of container supports 402 and storage containers 106.

[0168] As shown, the container supports 402 may preferably have a toroidal horizontal cross section. All of the container supports 402 will typically have the same geometric shape. The lowest container support 402 will differ from the others in that it will not have an opening 403 because there are typically no storage containers 106 or container spaces 104 to be reached below this container support 402.

[0169] In the exemplary drawing, the support structure 450 is a central pole, however, other arrangements are envisioned in which the container supports are mounted on circumferential bearings provided within a cylindrical framework that surrounds the container supports.

[0170] When arranged within a container support skeleton 401, the container supports 402 of Figures 7 and 8 may be divided into multiple container supports 402 arranged coaxially within the same container support skeleton 401. The container supports 402 of the same container support skeleton 401 may therefore be rotatable relative to one another. In this case, the first, second, and third container spaces 104c of the same container support skeleton 401 may be distributed across the first, second, and third container supports 402, respectively.

[0171] Alternatively, the container support 402 may be divided into compartments such that multiple first container spaces 104a are distributed over multiple container supports 402. Gaps between pairs of compartments may provide openings for the storage containers 106 to pass through.

[0172] FIG. 11 illustrates a storage tower 400 that includes at least one container support 402 aligned with a vertical axis A of a support structure 450. v 7 shows that the device may include a drive mechanism 700 configured to rotate the device relative to the

[0173] In Figure 11, some of the container supports 402 have been removed for illustrative purposes. The drive mechanism 700 may be connected to the support structure 450, the container support skeleton 401, or the container supports 402. In Figure 11, the drive mechanism 700 is connected to the vertical axis A of the support structure 450. v 4. The container 401 is connected to a portion of the container support skeleton 401 forming an arm 405 extending horizontally in a radial direction from the container 401.

[0174] The drive mechanism 700 may be, for example, a swivel drive, a gear drive, a belt drive, a chain drive, an electromagnetic drive such as a stepper motor, or the like.

[0175] Typically, all container supports 402 in a storage tower 400 will be rotatable. However, the lowest container support 402 may be stationary if all upper container supports 402 are rotatable so that a remotely operated vehicle can be vertically aligned above all potential target storage containers 106′ supported on the lowest container support 402.

[0176] Container support 402 may be at least indirectly rotationally connected to support structure 450, for example, via container support skeleton 401, which may be connected to support structure 450 in a non-rotational manner. In that case, container support skeleton 401 may be considered a stationary portion of storage tower 400.

[0177] 11 shows that the drive mechanism 700 may be connected to a stationary part (e.g., a container support skeleton) and configured to use a gear drive to rotate the container support 402. The container support 402 may have gears arranged proximate its center as in FIG. 11, or the gears may be arranged closer to or on its circumference.

[0178] 12 shows that the skeleton 401 can be used to support one container support 402. To enable rotation of the container support 402 relative to the container support skeleton 401, the container support skeleton 401 can be equipped with one or more rotation devices 406. The rotation devices 406 can be wheels, bearings, swivels, rollers. The container support 402 can therefore be considered to be rotationally coupled to a stationary part, in this case the container support skeleton 401. In an alternative configuration, the container support 402 can be equipped with such a rotation device and arranged to extend across a surface or track provided by the container support skeleton.

[0179] The rotation device 406 may be powered to rotate and thus form the drive mechanism 700 .

[0180] In FIG. 12, a rotation device 406 is arranged within the distal portion of the arm 405 .

[0181] If one container support framework 401 comprises multiple coaxially arranged container supports 402, as described above, each arm 405 may require a corresponding number of rotation devices 406. The rotation devices 406 may therefore rotate along the vertical axis A of the support structure 450 corresponding to the horizontal extension of the container supports 402. v the radial distance from the container support (e.g., the radial inner and outer extents of the container support).

[0182] Alternatively, each of the multiple container supports 402 may have a dedicated arm 405 having a different length according to the horizontal extent of the container support 402, or having the same length but with a rotation device 406 arranged in a different position according to the horizontal extent of the container support 402 to which it is to be rotatably connected.

[0183] The container support 402 may include guide posts 407 for guiding the storage container 106 into position over the container space 104. The storage container 106 may preferably include guide recesses configured to cooperate with the guide posts 407.

[0184] The container support 402 may, for example, have cutouts in the container space 104. These cutouts may reduce the weight and cost of the container support 402.

[0185] To store and retrieve the target storage container 106' using the storage tower 400, the following operations are performed (see Figures 6 and 5a-c). Control system 500 commands vehicle 301 to load target storage container 106' with coordinates X, Y, and Z. This position corresponds to storage container 106 being positioned within container space 104 of container support 402g at a depth of 5×ΔdV+Vr1 below rail system 408. All of the openings 403 in storage tower 400 are initially aligned (with the same XY coordinates), so that the XY position of target opening 403' in container support 402a adjacent rail system 408 is equal to the XY position of target opening 403' in underlying container support skeletons 401b-m. The vehicle 301 moves in the X and Y direction with the aid of its drive means 301b,c until its lifting device 304 is positioned directly above the target opening 403'. During and / or after movement of the vehicle 301 to a position above the target opening 403', the control system 500 sends commands to the drive mechanism 700 to rotate the container support 402g so that the target storage container 106' is vertically aligned with the target opening 403' of the upper mounted container support 402a-f. During and / or after the displacement of the container support 402g, the lifting device 304 of the vehicle 301 is activated and lowered downward through the grid opening 415 and the aligned target opening 403′ until the gripping portion of the lifting device 304 reaches a home position and grips the target storage container 106′. After the target storage container 106′ is grasped by the lifting device 304 and raised above the container support 402f, the drive mechanism 700 is activated again to move the container support 402g back to its initial position. · Once the target storage container 106' is raised above the rail system 408, the vehicle 301 is moved to another location on the rail system 408, for example, a dedicated port column / chute for delivery to an access station.

[0186] The present process has the advantage that the need to perform excavations performed for prior art storage and retrieval systems is no longer necessary.

[0187] 5a-c show grid openings 415 through which the lifting device 304 may access the storage container 106. The storage container 106, openings 403, and container space 104 of the container support 402 may be vertically aligned with this grid opening 415. Due to the rotational movement of the container support 402 and the rectangular shapes of the grid openings 415, storage container 106, openings 403, and container space 104, not all of the grid openings 415 are suitable access points. In some cases, only one grid opening 415 is a suitable access point throughout a full 360-degree rotation of the container support 402. By adjusting the size of the storage container 106, openings 403, container space 104, and / or grid openings 415, two suitable access points can be provided, offset by 180 degrees. By further squaring the storage containers 106, openings 403, container spaces 104, and grid openings 415, four suitable access points can be provided with a 90-degree offset. This is based on a container support 402 having only a plurality of first container spaces 104a. A container support 402 that also has a plurality of second storage spaces 104b can have twice the number of access points. A container support 402 that also has a plurality of third storage spaces 104c can have three times the number of access points, and so on.

[0188] FIG. 9 shows a side view of the storage and retrieval system 1 with one storage tower 400 of the present invention and one prior art storage grid 100. The drive mechanism 700 described above is arranged proximate the center of each container support 402. This particular configuration includes thirteen container supports 402a-m arranged directly beneath the rail system 408. The container supports 402a-m are arranged within a corresponding number of container support frameworks 401a-m. All container supports 402 are rotatable relative to one another. Other numbers of container supports 402 may be present as appropriate. Preferably, there are more than five container supports 402, and more preferably, there are more than ten.

[0189] A combined rail system 408' is seen, for example, in FIG. 15 , interconnecting the rail system 108 of the prior art storage grid 100 and the rail system 408 of the storage tower 400 of the present invention to enable movement between the storage grid 100 and the storage tower 400. The rail system 408 of the storage tower 400 of the present invention and the rail system 108 of the prior art storage grid 100 have a mutual orientation and design such that the same type of vehicle 301 can operate on both rail systems 108, 408. Due to the different construction of the container support 402 of the storage tower 400 of the present invention and the stack 107 of storage containers 106 of the prior art storage grid 100, the rails 410, 411 above the container support 402 may be made wider in at least one of the X and Y directions compared to the rails 110, 111 above the stack 107. To ensure a grid opening 415 through which the storage container 106 can pass, the rails 410, 411 above the container support 402 may be made deeper, i.e., in the Z direction.

[0190] Both the storage tower 400 of the present invention and the prior art storage grid 100 can be of any size. In particular, it should be understood that the storage tower 400 and / or storage grid 100 can be significantly wider and / or longer and / or deeper than those disclosed in the accompanying figures. For example, the storage tower 400 and / or storage grid 100 may have a horizontal extent with space for more than 700 x 700 storage containers 106 and a storage depth of more than 14 storage containers 106.

[0191] As explained above, one way to arrange a storage tower 400 can be to remove all stacks 107 of storage containers 106 and most of the vertical pillars 431 directly below the rail system 108 portion of the prior art storage and retrieval system 1, as shown in Figure 1, leaving only the cantilever portion CP of the rail system 108 and several vertical pillars 431 as shown in Figure 10. The next step is to insert one or more storage towers 400 of the present invention into the empty volume below the cantilever portion CP of the rail system 108. Figure 10 illustrates how some of the container supports 402 can be removed and the container support skeletons 401 can be installed on top of each other without spaces between them.

[0192] Figure 13 illustrates an embodiment of a storage and retrieval system 1 in which multiple storage towers 400 are arranged side-by-side and adjacent to a storage grid 100. In the example of Figure 13, three storage towers 400 and one storage grid are arranged below the same rail system 108. In the example of Figure 14, one storage tower 400 and one storage grid are arranged below the same rail system 108.

[0193] FIG. 14 shows a storage tower 400 with multiple container supports 402a-m. This example shows thirteen container supports 402. The fourth container support 402d, counting from the top, has an empty container space 106''. The sixth container support 402f, counting from the top, also has an empty container space 106''.

[0194] In the foregoing description, various aspects of an automated storage and retrieval system and associated method for loading product items using vehicles have been described with reference to illustrative embodiments. For purposes of explanation, specific numbers, systems, and configurations have been set forth to provide a thorough understanding of the system and its operation. 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, that are apparent to those skilled in the art to which the disclosed subject matter pertains are deemed to be within the scope of the present invention.

[0195] List of Reference Numbers [Table 1-1] [Table 1-2]

Claims

[Claim 1] The invention described in this specification.

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