Power supply for load handling devices operating on a lattice framework structure

Abstract

A method for replacing a power supply 50 in a load handling device 31 operable on a lattice framework structure 1, the method comprising the steps of: a) removing a first power supply 50a from the load handling device 31; b) inserting the first power supply 50a into a first storage container 9a in a first lattice cell 14a; c) removing a second power supply 50b from a second storage container 9b in a second lattice cell 14b; and d) inserting the second power supply 50b into the load handling device 31.

Description

[Technical field]

[0001] The present invention relates to the field of replacing power sources for load handling devices operating on a track system of a lattice framework structure that supports remotely operated load handling devices on tracks disposed thereon for handling storage containers stacked within the lattice framework structure. [Background technology]

[0002] The claimed invention seeks to provide improvements regarding energy storage systems for load handling devices operating in automated storage and retrieval systems.

[0003] The load handling devices are typically powered by a rechargeable power source which, once depleted, needs to be recharged to allow the load handling device to continue to operate, which can take a significant amount of time and reduce the effective operating time of the load handling device.

[0004] If the rechargeable power source is a battery, the relatively long charging time of the battery may extend to several hours, which represents a significant downtime during which the load handling device remains inactive or inoperable. Where several load handling devices are operable in an automated storage and retrieval system to fulfill customer orders within a given time slot, leaving one or more load handling devices idle for a significant amount of time adversely affects the ability of a fulfillment center or distribution warehouse to fulfill orders in a timely manner. This is particularly the case where the load handling devices contribute to a logistics system that provides home delivery of goods to a customer's premises upon receipt of an order for the goods. Here, delivery information including a delivery address is used by online retailers such as Amazon and Ocado in the UK to deliver goods to the customer's delivery address. To mitigate such issues, online retailers such as Ocado in the UK provide a buffer of load handling devices operable on a lattice framework structure track system to accommodate load handling devices that remain idle for charging. In extreme cases, the time slot for delivery of an order is extended to account for this downtime.

[0005] Typically, a load handling device powered by a lithium ion battery requires 15 minutes of charging for every 4 hours of discharging.

[0006] An alternative to charging the rechargeable power source at a charging station is for the rechargeable power source to be swappable, so that a depleted rechargeable power source in the load handling device can be replaced with a fully charged rechargeable power source. Swapping a rechargeable power source is much faster than charging the rechargeable power source while it is in the load handling device, thus eliminating the drawbacks of slow battery charging, reducing downtime, and contributing to efficiently fulfilling customer orders.

[0007] Typically, a load handling device with a depleted rechargeable power source is moved to a replacement station where the depleted rechargeable power source is removed. The load handling device must then be moved to a second replacement station to have a fully charged rechargeable power source installed.

[0008] However, when the rechargeable power source is removed from the load handling device, the load handling device temporarily loses its power supply, which poses two problems: power is needed to enable the load handling device to move to another exchange station to receive a new rechargeable power source, and losing power means that the load handling device loses communication with its control system.

[0009] To solve these problems, an auxiliary power source can be provided to the load handling device to enable it to be moved to another exchange station and still maintain connection to the control system.

[0010] In some instances, the rechargeable power source can be removed and a new one installed at the same replacement station. This is more efficient than requiring the load handling device to visit two different replacement stations, but the replacement still requires some work (removing the depleted rechargeable power source from the load handling device, moving the depleted rechargeable power source out of the way, and installing the new rechargeable power source). An auxiliary power source is still required to keep the load handling device powered during the replacement operation.

[0011] WO2018210923 (AutoStore) discloses a load handling device having a protrusion that protrudes into an adjacent grid space, the protrusion comprising a replaceable battery and a battery compartment. In one embodiment, the load handling device interfaces with a first charging station to remove a depleted battery and travels under auxiliary power to a second charging station to retrieve a charged battery. https: / / worldwide.espacenet.com / patent / search / family / 062167358 / publication / WO2018210923A1?q=WO2018210923

[0012] WO2019206440A1 (AutoStore) also discloses a capacitor power supply for powering a load handling device as an auxiliary power source for backup or when moving between battery exchange stations during a battery exchange operation. https: / / worldwide.espacenet.com / patent / search / family / 063834034 / publication / WO2019206440A1?q=WO2019206440A1

[0013] The use of an auxiliary power source solves the problem of how to maintain power to the load handling device and provide enough power to move the load handling device to a second station where a new power source can be provided, but has the disadvantage that the auxiliary power source is an additional component with attendant costs and maintenance requirements. The need for the load handling device to move to a second station means an additional move is required, which further reduces the time that the load handling device is not fulfilling customer orders and also requires additional power. Also, the control system is more complex and requires algorithms to determine the location of an appropriate station where a replacement power source can be installed in the load handling device.

[0014] Therefore, there is a need for a method for quickly and easily replacing a power supply in a load handling device. Summary of the Invention

[0015] In one aspect, the present invention provides a method for replacing a power source in a load handling device operable on a lattice framework structure, the lattice framework structure comprising: i) a track system comprising a first set of tracks extending in a first direction and a second set of tracks extending in a second direction, the second direction being substantially perpendicular to the first direction, the track system extending in a substantially horizontal plane and forming a grid pattern comprising a plurality of grid cells; ii) a plurality of upright columns supporting the track system; and iii) a plurality of stacks of storage containers disposed in a plurality of storage columns positioned below the track system; The method is: a) removing a first power source from a load handling device; b) inserting a first power source into a first storage container in a first grid cell; c) removing a second power source from a second storage container in a second grid cell; and d) inserting a second power source into the load handling device.

[0016] This method advantageously provides a faster method of replacing the power supply. Since the exchange of power supply is actually performed on the lattice framework structure, the load handling device does not need to travel to different locations to provide a charged power supply, which saves time and energy, which in turn improves the operation efficiency of the load handling device.

[0017] The first and second storage containers may be configured to house a power source or multiple power sources.

[0018] The method may further include commanding the second load handling device to remove the first storage container housing the first power source from the first grid cell. The first power source may be a depleted power source that has run out of charge, and the second power source may be a fully charged power source. The first storage container may be removed from the first grid cell when it houses at least one power source (i.e., the first power source), or the first storage container may be removed when it is full, i.e., when it houses the same number of power sources as it is configured to house. The second load handling device may be the same load handling device, i.e., the load handling device undergoing a power source replacement, or a different load handling device.

[0019] The method may further include the step of instructing the third load handling device to place an empty storage container in the first grid cell, which is effectively replacing the first storage container just removed from the first grid cell with the empty storage container. The empty storage container may then be used to accommodate the additional power source removed from the additional load handling device. The third load handling device may be the same load handling device, i.e., the same load handling device undergoing replacement of the power source, or a different load handling device. Also, the third load handling device may be the second load handling device or another load handling device.

[0020] The method may further include charging the first power source after the first storage container is removed from the first lattice cell. If the power source is rechargeable, the first storage container housing the first power source after removal from the first lattice cell in the lattice framework structure may be transported to a charging station where the first power source may be charged. If the power source is not rechargeable, the first storage container housing the first power source after removal from the lattice framework structure may be transported to a disposal area where the first power source may be disposed of.

[0021] The advantage of charging the first power source after removing it from the lattice framework structure is safety: charging can be carried out in a separate area with appropriate fire protection and fire resistance mechanisms, rather than within the lattice framework structure.

[0022] The method may further include commanding a fourth load handling device to remove the second storage container from the grid cell. The fourth load handling device may be the same load handling device, i.e., the load handling device undergoing the power exchange, or a different load handling device. Additionally, the fourth load handling device may be the second and / or third load handling device, or a different load handling device.

[0023] The method may further include commanding a fifth load handling device to place a storage container including one or more power sources in the second grid cell. The fifth load handling device may be the same load handling device, i.e., the load handling device undergoing the power source replacement, or a different load handling device. Additionally, the fourth load handling device may be the second load handling device and / or the third load handling device and / or the fourth load handling device, or a different load handling device.

[0024] Removing the second storage container from the second grid cell and placing a storage container containing one or more power sources effectively refreshes the supply of charged power sources available for replacement. For example, when a second storage container becomes empty because all of the power sources it previously contained have been removed and inserted into the load handling device, a replacement container containing one or more fully charged power sources may be provided to ensure that fully charged power sources are available for insertion into the load handling device.

[0025] In some examples, when the second storage container is empty, the storage container can be removed from the lattice framework structure. In other examples, when the first storage container is removed from the lattice framework structure, an empty second storage container can be used to replace the first storage container.

[0026] Once the second storage container is emptied, it can be replaced with another storage container that includes a fully charged power source. In some examples, the replacement storage container that includes one or more fully charged power sources can be brought into the lattice framework structure by a load handling device lifting the storage container up to the port column, traveling on the track system, and placing the second storage container into the lattice framework structure.

[0027] The load handling device may include a securing mechanism configured to releasably secure the power source within the load handling device. The securing mechanism may also provide an electrical coupling between the power source and a drive mechanism for driving the load handling device on the track system. This has the advantage of a simpler construction with fewer parts. Instead of two separate systems for securing the power source and for electrically coupling the power source, one system can perform both functions.

[0028] The load handling device may include an auxiliary power source, which advantageously allows the load handling device to maintain power to auxiliary systems (e.g., communication with the control system) while the power source is being replaced.

[0029] The first and / or second storage containers may include one or more compartments configured to house the power source. If the power source is a battery, it is important for safety reasons that the live terminals of the power source do not touch and cause a short circuit. This applies to both fully charged and depleted batteries. Having separate compartments within the first and / or second storage containers helps achieve this goal by keeping the power sources separate and ensuring that the power sources are secured and cannot tip over or move within the storage container. In some examples, the compartments may be formed from insulating separators configured to keep the power source upright.

[0030] Other fire resistance measures may be applied to the storage container and / or the lattice framework structure: for example, the material of the storage container may be fire resistant, the storage container may release a fire suppressant to contain any fire, or the lattice framework structure itself may be equipped with sprinklers or other systems to contain and / or extinguish fires.

[0031] The first storage container may include a fire suppression container that includes a fire suppression material for safely containing an overheating power source. The overheating power source may be a power source that has exceeded a predetermined threshold temperature, for example, at or slightly above the maximum operating temperature of the power source. For example, the fire suppression material may be a granular material, such as glass, perlite, or vermiculite. When the power source catches fire, the fire suppression material melts and absorbs heat from the power source, thereby providing a cooling effect that aids in extinguishing the fire. The molten fire suppression material also forms an impermeable layer around the power source, thus preventing oxygen from the air from reaching the power source, which also aids in extinguishing the fire. The advantage of using a granular material is that the material is densely packed and has a large surface area, which allows the fire suppression material to closely surround the overheating power source and melt quickly, and the large surface area is effective in absorbing liquids.

[0032] In another aspect, the present invention provides an apparatus for replacing a power source of a load handling device on a track system of a grid framework structure, comprising: the track system includes a first set of tracks extending in a first direction and a second set of tracks extending in a second direction, the second direction being substantially perpendicular to the first direction; The lattice framework structure includes a track system, a plurality of upright columns supporting the track system, and a plurality of stacks of storage containers disposed in the storage columns located below the track system; The apparatus includes a robot base disposed on a lattice cell and a robot arm coupled to the robot base; The robotic arm is configured to perform the methods described herein.

[0033] In another aspect, the present invention provides a system for replacing a power source in a load handling device on a lattice framework structure, the system comprising: i) a lattice framework structure including a track system including a first set of tracks extending in a first direction and a second set of tracks extending in a second direction, the second direction being substantially perpendicular to the first direction, the track system extending substantially in a horizontal plane and forming a lattice pattern including a plurality of lattice cells; ii) a plurality of upright columns for supporting the track system; and iii) a plurality of stacks of storage containers disposed in a plurality of storage columns positioned below the track system; iv) a load handling device comprising a first power source for providing power for moving the load handling device on the track system; and v) a first storage container in the first grid cell; vi) a second storage container housing a second power source for the load handling device, the storage container being disposed within the second grid cell; vii) picking means configured to remove / insert power to the load handling device.

[0034] The power source is replaced by a picking means configured to remove / insert the power source from / into the load handling device. The picking means may be any means capable of picking up and moving the power source, such as a robotic arm, a gripper, a crane, a magnet, a human worker, or a manual tool operated by a human worker (e.g., a gripper or a pair of tongs).

[0035] The system may further comprise a control system configured to control the picking means to carry out the methods described herein.

[0036] The picking means may comprise a robot comprising a robot base and a robot arm coupled to the robot base, the robot base being located on a third grid cell of the track system.

[0037] The system is i) a robot comprising a robot base and a robot arm coupled to the robot base, the robot base being positioned on a third grid cell of the track system; ii) a control system including a processor and data storage means including computer executable instructions which, when executed by the processor, cause the robot to replace the first power source with a second power source in the load handling device.

[0038] Advantageously, the robot arm can reach grid cells adjacent to the third grid cell in which the robot base is located. In some examples, the robot arm can reach grid cells that are not adjacent to the third grid cell in which the robot base is located. Advantageously, this means that one robot arm can service a range of grid cells and therefore a load handling device does not have to move up to it to swap its power supply. Also, one robot arm can efficiently swap the power supplies of multiple load handling devices, and if several load handling devices form a queue to be serviced by the same robot arm, there is enough space for several load handling devices around the third grid cell so that the next load handling device in the queue does not have to wait for the previous load handling device in the queue to move out of the way to approach the third grid cell. Thus, a fast and efficient swap can be achieved.

[0039] In some examples, the robotic arm may be movable with six degrees of freedom, which advantageously provides flexibility of movement so that the power source may be easily moved to a required location within a load handling device or storage container. In other examples, the robotic arm may be mounted to a gantry crane.

[0040] The robotic arm may be provided with an end effector, such as a clamping device or a suction cup, to facilitate holding and lifting the power supply.

[0041] The robot base may be mounted to the third lattice cell, advantageously providing stability to the robot base.

[0042] The robot base may be provided with a wheel assembly and configured to move on the track system of the lattice framework structure. Advantageously, this allows the robot base to service a larger area of ​​the track system. This also has the advantage that if the load handling device is fully discharged and does not have enough power to move on the track system, the robot base can approach the load handling device to replace its power source. Otherwise, the load handling device will get stuck on the track system and operation of the lattice framework structure will need to be paused to retrieve the load handling device.

[0043] The control system may be further configured to command the robot to place a first power source in a first storage container in the first grid cell.

[0044] The control system may be further configured to command the second load handling device to remove the first storage container housing the first power source from the first grid cell. The second load handling device may be a load handling device.

[0045] The control system may be further configured to command a third load handling device to place the empty storage container in the first grid cell. The third load handling device may be a load handling device.

[0046] The control system may be further configured to command a fourth load handling device to remove the second storage container from the second grid cell. The fourth load handling device may be a load handling device.

[0047] The control system may be further configured to command a fifth load handling device to place a storage container including the one or more power sources within the second grid cell. The fifth load handling device may be a load handling device.

[0048] As mentioned above, any or all of the second, third, fourth, and fifth load handling devices may be the same load handling device undergoing a power exchange, or different load handling devices. Additionally, any of the second and / or third and / or fourth and / or fifth load handling devices may be the same load handling device or different load handling devices.

[0049] The first container may be a fire suppression container that contains fire suppression materials to safely contain the overheating power source.

[0050] Batteries, mainly based on lithium-ion, nickel-cadmium, nickel-metal hydride, or lithium-ion polymer battery technology, rely on chemical reactions to store electrical energy. For the purposes of the present invention, the term battery is taken to mean a battery pack consisting of one or more electrochemical cells with an external connector, i.e., a positive terminal and a negative terminal. An optional external connector may be present on the battery to send signals regarding the battery's condition. The individual electrochemical cells that make up the battery can be connected in series and / or in parallel. The effectiveness of these batteries decreases after repeated charging due to the breakdown of the lithium-ion cells, and therefore the ability of the battery to store charge for long periods of time decreases over time. Exchangeable rechargeable power sources have the advantage that removing the power source is a normal part of the operation of the load handling device, rather than a separate maintenance operation, and therefore, when the old battery should be withdrawn from use, it can be simply pulled from circulation without requiring additional maintenance operations when it is removed from the load handling device at the exchange station.

[0051] Further features and aspects of the present invention will become apparent from the following detailed description of illustrative embodiments which proceeds with reference to the drawings. [Brief description of the drawings]

[0052] [Figure 1]FIG. 1 illustrates a schematic of a lattice framework structure and a storage container. [Diagram 2] FIG. 2 illustrates a schematic of a track on top of the lattice framework structure illustrated in FIG. [Diagram 3] FIG. 3 illustrates diagrammatically a load handling device on the lattice framework structure illustrated in FIG. [Figure 4] FIG. 4 illustrates diagrammatically a single load handling device with the container lifting means in a lowered configuration. [Diagram 5] FIG. 5 illustrates diagrammatically a cut-away view of a single load handling device with its container lifting means in a raised and lowered configuration. [Figure 6] FIG. 6 is a flow chart illustrating a method for replacing a power supply in accordance with one embodiment of the present invention. [Figure 7] FIG. 7 is a schematic diagram illustrating a method of replacing a power supply according to one embodiment of the present invention. [Figure 8] FIG. 8 shows a perspective view of a robotic arm according to an embodiment of the present invention. [Figure 9] FIG. 9 is a perspective view of a robotic arm attached to a lattice cell of a lattice framework structure. [Figure 10] FIG. 10 is a perspective view of a robotic arm attached to a lattice cell of a lattice framework structure. [Figure 11] FIG. 11 is a perspective view of a load handling device and a robotic arm on a lattice framework structure. [Figure 12] FIG. 12 is a perspective view of a load handling device and a robotic arm mounted in a lattice cell of a lattice framework structure. [Figure 13] FIG. 13 is a perspective view of a robotic arm having an end effector with a clamping device. [Figure 14] FIG. 14 is a flow chart illustrating a method for replacing a power supply in a load handling device if the power supply is overheating. [Figure 15]15(a)-(c) show schematic diagrams of a fire suppression container partially filled with granular fire suppression material. [Figure 16] 16(a)-(d) show schematic diagrams of a fire suppression container partially filled with granular fire suppression material contained in pouches. [Figure 17] FIG. 17 illustrates an exemplary power exchange station in the form of a robot located on a platform adjacent the perimeter of a portion of the track system. [Figure 18] FIG. 18 illustrates an exemplary power supply exchange station having a power supply holder positioned on a horizontal surface within a storage structure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0053] While the following embodiments represent Applicant's preferred examples of how to implement adapted orbital elements, they are not necessarily the only examples of how it may be accomplished.

[0054] Storage and Retrieval Systems 1 illustrates a lattice framework structure 1 comprising upright members 3 and horizontal members 5, 7 supported by the upright members 3. The horizontal members 5 extend parallel to each other and to an illustrated x-axis. The horizontal members 7 extend parallel to each other and to an illustrated y-axis and transverse to the horizontal members 5. The upright members 3 extend parallel to each other and to an illustrated z-axis and transverse to the horizontal members 5, 7. The horizontal members 5, 7 form a lattice pattern defining a plurality of lattice cells. In the illustrated example, storage containers 9 are arranged in stacks 11 below the lattice cells defined by the lattice pattern, one stack 11 of storage containers 9 per lattice cell.

[0055] FIG. 2 shows an enlarged plan view of a section of a track system or track system 13 that is illustrated on top of the horizontal members 5, 7 of the illustrated lattice framework structure 1 of FIG. 1 and forms part of the lattice framework structure 1 located therein. The track system 13 may be provided by the horizontal members 5, 7 themselves (e.g., formed in or on the surface of the horizontal members 5, 7) or by one or more additional components attached to the top of the horizontal members 5, 7. The illustrated track system 13 comprises an x-direction track 17 and a y-direction track 19, i.e., a first set 17 of tracks extending in the x-direction and a second set 19 of tracks extending in the y-direction transverse to the tracks 17 in the first set 17 of tracks. The tracks 17, 19 define apertures 15 in the center of the lattice cells. The apertures 15 are sized to allow a storage container 9 located below the lattice cell to be lifted and lowered through the apertures 15. The x-direction tracks 17 are provided in pairs separated by channels 21, and the y-direction tracks 19 are provided in pairs separated by channels 23. Other arrangements of the track system are possible.

[0056] As an alternative to the lattice framework structure 1 supporting the two-dimensional track system 13 directly on the upright members 3 as shown in FIG. 1, in another example, the lattice framework structure 1 supports the track system 13 on a plurality of prefabricated modular panels arranged in a lattice pattern, the details of which are briefly described below and fully described in PCT application WO2022034195A1 in the name of Ocado Innovation Ltd and incorporated herein by reference. This lattice framework structure described in WO2022034195A1 addresses the time and cost issues to assemble by supporting a 2D lattice on a supporting framework structure comprising a plurality of prefabricated modular panels arranged in a three-dimensional lattice pattern to define a plurality of lattice cells. Each of the lattice cells of the supporting framework structure is sized to support two or more lattice cells of the lattice on which the load handling device operates. The lattice framework structure is formed from fewer structural components, yet maintains the same structural integrity as the typical "stick-built" lattice framework structure 1 described above in which each node of the track system is supported by one upright member, and is much faster and cheaper to build.

[0057] The prefabricated modular panels of the lattice framework structure 1 described above comprise upright members 3. For example, subgroups of upright members may be braced by one or more bracing members to form a prefabricated panel or frame. For purposes of the present invention, upright members 3 may also include upright members within a prefabricated panel. The lattice framework structure 1 may comprise any suitable supporting framework structure for supporting the lattice, including upright members 3 that directly support the lattice, and / or prefabricated panels and / or frames incorporating upright members 3.

[0058] Figure 3 shows multiple load handling devices 31 moving on top of the lattice framework structure 1 illustrated in Figure 1. The load handling devices 31, which may also be referred to as robots 31 or bots 31, are provided with a set of wheels for engaging with corresponding x-direction tracks 17 or y-direction tracks 19 to enable the load handling devices 31 to move across the track system 13 and reach a particular lattice cell. The illustrated pair of tracks 17, 19 separated by channels 21, 23 allows the load handling devices 31 to occupy adjacent lattice cells (or pass each other) without colliding with each other.

[0059] 4, the load handling device 31 comprises a body 33 having one or more components therein or attached thereto that enable the load handling device 31 to perform its intended functions. These functions may include traveling throughout the storage structure 1 on the track system 13 and raising or lowering containers 9 (e.g., to or from stacks 11) so that the load handling device 31 may retrieve or place containers 9 at specific locations defined by a grid pattern.

[0060] The load handling device 31 may include a wheel assembly 34. The embodiment of the load handling device 31 illustrated in FIG. 4 includes a first set of wheels 35 and a second set of wheels 37 that are attached to the body 33 of the load handling device 31 and allow the load handling device 31 to move along the tracks 17 and 19, respectively, in the x and y directions. In particular, two wheels 35 are provided on the short side of the bot 31 visible in FIG. 4 and two more wheels 35 are provided on the opposite short side of the load handling device 31 (the side and the two more wheels 35 are not visible in FIG. 4). The wheels 35 engage the track 17 and are rotatably attached to the body 33 of the load handling device 31 to allow the load handling device 31 to move along the track 17. Similarly, two wheels 37 are provided on the long side of the bot 31 visible in Figure 4, and two more wheels 37 are provided on the opposite long side of the load handling device 31 (the side and the two more wheels 37 are not visible in Figure 4). The wheels 37 engage the track 19 and are rotatably mounted to the body 33 of the load handling device 31, enabling the bot 31 to move along the track 19.

[0061] The wheel assembly 34 of the load handling device 31 may be driven by a drive mechanism 38. The drive mechanism 38 may include one or more motors.

[0062] The load handling device 31 also comprises container lifting means 39 configured to raise and lower the storage container 9. The illustrated container lifting means 39 comprises four tapes or reels 41, which are connected at their lower ends to a container engaging assembly 43. The container engaging assembly 43 comprises engagement means configured to engage features of the storage container 9, which may for example be provided at the corners of the assembly 43, in the vicinity of the tapes 41. For example, the storage containers 9 may be provided with one or more apertures on their upper side with which the engagement means may engage. Alternatively or additionally, the engagement means may be configured to hook under a rim or lip of the storage container 9 and / or to clamp or grip the storage container 9. The tapes 41 may be wound up or unwound to raise or lower the container engaging assembly as required. The container lifting means 39 may be driven by a drive mechanism 38. Winding or unwinding of the tape 41 on the container lifting means 39 may be performed or controlled by a drive mechanism 38, which may comprise one or more motors or other means. The same drive mechanism 38 may be used to drive both the wheel assembly 34 and the container lifting means 39, or separate drive mechanisms may be used.

[0063] As seen in FIG. 5 , the body 33 of the illustrated load handling device 31 has an upper portion 45 and a lower portion 47. The upper portion 45 is configured to accommodate one or more operating components (not shown). The lower portion 47 is disposed below the upper portion 45. The lower portion 47 comprises a container receiving space 49 or cavity for accommodating at least a portion of a storage container 9 lifted by the container lifting means 39. The container receiving space 49 is sized such that the storage container 9 can fit sufficiently inside the cavity to allow the load handling device 31 to move across the track system 13 on top of the lattice framework structure 1 without the underside of the storage container 9 getting caught on the track system 13 or another part of the lattice framework structure 1. When the load handling device 31 reaches its intended destination, the container lifting means 39 controls the tape 41 to lower the container engaging assembly 43 and the corresponding storage container 9 out of the container receiving section 49 in the lower portion 47 and into the intended position. The intended location may be an exit point of the stack 11 of storage containers 9 or the lattice framework structure 1 (or an entry point of the lattice framework structure 1 if the load handling device 31 moves to collect containers 9 relative to the lattice framework within the lattice framework structure 1). In the illustrated example, the upper portion 45 and the lower portion 47 are separated by a physical divider, although in other embodiments the upper portion 45 and the lower portion 47 may not be physically separated by a particular component or part of the body 33 of the load handling device 31.

[0064] In some embodiments, the container receiving space 49 of the load handling device 31 may not be within the body 33 of the load handling device 31. For example, in some embodiments, the container receiving space 49 may be adjacent to the body 33 of the load handling device 31, for example in a cantilever configuration with the weight of the body 33 of the load handling device 31 counterbalancing the weight of the container being lifted. In such an embodiment, the frame or arm of the container lifting means 39 may project horizontally from the body 33 of the load handling device 31, and the tape / reel 41 may be arranged at respective locations on the projecting frame / arm and configured to be raised and lowered from those locations to raise and lower the container into the container receiving space 49 adjacent the body 33. The height at which the frame / arm is attached to and projects from the body 33 of the load handling device 31 may be selected to provide a desired effect. For example, it may be preferred that the frame / arm projects at a high level above the body 33 of the load handling device 31 so that a larger container (or multiple containers) can be lifted into the container receiving space below the frame / arm. Alternatively, the frame / arms may be positioned to protrude below the body 33 (but high enough to accommodate at least one container between the frame / arms and the track system 13), keeping the center of mass of the load handling device 31 lower when containers are loaded onto the load handling device 31.

[0065] To enable the load handling device 31 to move in first and second directions on different wheels 35, 37, the load handling device 31 includes a wheel positioning mechanism for selectively engaging the first set of wheels 35 with the first set of tracks 17 or the second set of wheels 37 with the second set of tracks 19. The wheel positioning mechanism is configured to raise and lower the first set of wheels 35 and / or the second set of wheels 37 with respect to the body 33, thereby enabling the load handling device 31 to selectively move in either a first direction or a second direction across the tracks 17, 19 of the lattice framework structure 1.

[0066] The wheel positioning mechanism may include one or more linear actuators, rotary components, or other means for raising and lowering at least one set of wheels 35, 37 relative to the body 33 of the load handling device 31 to move the at least one set of wheels 35, 37 off of and into contact with the tracks 17, 19. In some examples, only one set of wheels is configured to raise and lower, such that the act of lowering one set of wheels can effectively lift the other set of wheels away from the corresponding tracks, while the act of raising one set of wheels can effectively lower the other set of wheels into contact with the corresponding tracks. In other examples, both sets of wheels may be raised and lowered, advantageously meaning that the body 33 of the load handling device 31 remains at substantially the same height, thus not requiring the weight of the body 33 and the components mounted thereon to be raised and lowered by the wheel positioning mechanism.

[0067] The wheel assembly 34 and the drive mechanism 38 used to drive the container lifting means 39 may be powered by a power source 50 .

[0068] In some examples, the lattice framework structure 1 may include one or more port columns or vertical chutes to facilitate the entry or removal of storage containers into or from the lattice framework structure. A port column occupies one lattice cell bounded at four corners by four vertical uprights of the lattice framework structure. Vertical guides may be provided to guide the storage container vertically. To remove a storage container from the lattice framework structure 1, the load handling device 31 carrying the storage container 9 in its container receiving space 49 moves into the lattice cell at the top of the port column and lowers the storage container 9 until it reaches the bottom of the port column. The container engagement assembly 43 of the load handling device 31 is then disengaged from the storage container 9 and lifted back into the body 33 of the load handling device. The storage container 9 at the bottom of the port column may then be removed, for example, by a conveyor belt or a vehicle or human operation.

[0069] The same operation is used in reverse to place a storage container 9 into the lattice framework structure 1. The storage container 9 is brought to the bottom of the port column (e.g., by conveyor belt or vehicle or human operation). The load handling device 31 moves to a lattice cell at the top of the port column and lowers its container engaging assembly 43 down the port column. The container engaging assembly engages the storage container and the container lifting means 39 lifts the storage container 9 through the port column and into the container receiving space 49 of the load handling device 31. The load handling device then moves on the track system to bring the storage container to its destination position within the lattice framework structure.

[0070] How to replace power supply FIG. 6 is a flow chart illustrating a method of replacing a power source 50 in a load handling device 31 according to one embodiment of the present invention. Replacing a power source 50 may be required, for example, when a power source currently installed in the load handling device is depleted and no longer has a sufficient charge to power the drive mechanism 38 of the load handling device. In other instances, the power source may be faulty or in need of maintenance. In the following description, the power source 50 that is removed from the load handling device 31 is referred to as the first power source 50a, and the power source that is installed in the load handling device 31 in place of the first power source 50a is referred to as the second power source 50b. The storage container 9 in which the first power source 50a is located is referred to as the first storage container 9a, and the storage container 9 housing the second power source 50b before the second power source 50b is installed in the load handling device 31 is referred to as the second storage container 9b. The first storage container 9a is located in the first lattice cell 14a of the lattice framework structure, and the second storage container 9b is located in the second lattice cell 14b. In some examples, the first power source 50a may be a partially or completely depleted power source, have a fault, or require maintenance, and the second power source 50b may be a new or fully charged power source.

[0071] The power source is replaced by a picking means configured to remove / insert the power source from / into the load handling device. The picking means may be any means capable of picking up and moving the power source, such as a robotic arm, a gripper, a crane, a magnet, a human worker, or a manual tool operated by a human worker (e.g., a gripper or a pair of tongs).

[0072] As shown in the flow chart of FIG. 6, in a first step 60, the first power source 50a is removed from the load handling device 31. In a second step 62, the first power source 50a is placed or inserted into the first storage container 9a in the first grid cell 14a. In a third step 64, the second power source 50b is removed from the second storage container 9b in the second grid cell 14b. In a fourth step 66, the second power source 50b is inserted into the load handling device 31. The steps of removing the first power source 50a from the load handling device and replacing it with the second power source 50b stored in the second grid cell 14b may be performed by a robot attached to the track system. Further details of the robot are discussed below.

[0073] Figure 7 shows the same method in a different representation. A load handling device 31, a first and a second power source 50a, 50b, a first and a second storage container 9a, 9b, and a first and a second grid cell 14a, 14b are shown. The arrows represent the method steps 60, 62, 64, 66 of the flow chart of Figure 6 and indicate the transfer of the first and the second power sources 50a, 50b from and to the load handling device and to and from the first and the second containers 9a, 9b in the respective first and the second grid cells 14a, 14b. The first and the second grid cells 14a, 14b are shown diagrammatically for illustrative purposes only, are not to scale, and do not represent their actual or relative positions.

[0074] After the first power source 50a has been removed from the load handling device 31 and placed in the first storage container 9a in the first grid cell 14a, the first storage container 9a housing the first power source 50a can be removed from the first grid cell 14a and from the grid framework structure 1. If the first storage container 50a is configured to hold more than one power source, advantageously the first storage container 50a may be removed when it is full, i.e. after several power source exchange operations have been performed on several load handling devices 31, and the first storage container 9a may be removed when it houses as many power sources 50 as it is configured to house. This has the advantage that several exhausted power sources can be removed from the grid framework structure in one operation.

[0075] The removal of the first storage container 9a from the first grid cell 14a of the lattice framework structure can be performed by the second load handling device 31. This can be the same load handling device with the power supply replaced or a different load handling device. To remove the first storage container 9a from the first grid cell 14a of the lattice framework structure 1, the second load handling device 31 can be commanded to move on the track system 13 to the grid cell under which the first storage container 9a is located, i.e. the first grid cell 14a. The second load handling device 31 can then lower its container engagement assembly 43, grip the first storage container 9a and lift the first storage container 9a into the container receiving space 49 using the container lifting means.

[0076] The second load handling device 31 can then travel on the track system to a grid cell above the port column, lower the first storage container 9a down the port column, and disengage the container engaging assembly from the first storage container 9a. Upon reaching the bottom of the port column, the first storage container 9a can be carried away by human labor, a conveyor belt, another vehicle, or any other suitable means.

[0077] A dedicated port column may be provided for the storage containers containing the power source. For improved safety, the port column may be provided with fire-resistant walls, a sprinkler system, or any other suitable fire protection measures. This is particularly important when the power source is a battery.

[0078] The method may further include charging the first power source after the first storage container is removed from the first lattice cell of the lattice framework structure. If the power source is rechargeable, the first storage container housing the first power source after removal from the lattice framework structure may be transported to a charging station where the first power source may be charged. If the power source is not rechargeable, the first storage container housing the first power source after removal from the lattice framework structure may be transported to a disposal area where the first power source may be disposed of.

[0079] The advantage of charging the first power source 50a after removing it from the lattice framework structure 1 is safety: charging can be carried out not within the lattice framework structure 1 but in a separate area with appropriate fire protection and fire resistance mechanisms.

[0080] When the first storage container 9a is removed from the first lattice cell 14a of the lattice framework structure 1, it can be replaced with an empty storage container 9 to accommodate the further power supply 50 that was removed from the further load handling device 31. The empty storage container 9 can be brought to the first lattice cell 14a by a third load handling device 31. The third load handling device 31 can be the same load handling device whose power supply was replaced, and / or a second load handling device, or a different load handling device.

[0081] After the second power source 50a has been removed from the second storage container 9b in the second lattice cell 14b and placed in the load handling device 31, the second storage container 9b that previously housed the second power source 50b can be removed from the second lattice cell 14b of the lattice framework structure 1. If the second storage container 50b is configured to hold more than one power source 50, advantageously the second storage container 50b may house several power sources to allow several power source exchange operations to be performed for several load handling devices 31. After all the power sources 50 have been removed from the second storage container 9a, the second storage container 9b can be removed from the second lattice cell 14b and from the lattice framework structure. This may be performed by a fourth load handling device 31 picking up the second storage container 9b, moving it on the track system 13 to a grid cell above the port column, and lowering the second storage container 9b down the port column. Alternatively, an empty second storage container 9b may be used to replace the first storage container 9a when the first storage container 9b becomes full. The fourth load handling device may be a separate load handling device from the load handling device that just received the second power source from the second storage container, or may be the same load handling device that receives the second power source. The fourth load handling device may be the second and / or third load handling device, or a different load handling device.

[0082] When the second storage container 9b becomes empty because all the power sources 50 it previously housed have been removed and inserted into the load handling device 31, a replacement storage container 9 containing one or more fully charged power sources 50 may be provided to ensure that a fully charged power source 50 is available for insertion into the load handling device 31. The replacement storage container containing the one or more fully charged power sources may be brought into the lattice framework structure by the fifth load handling device lifting the storage container up to the port column, moving it on the track system, and placing the second storage container in the required position within the lattice framework structure. The fifth load handling device 31 may be the same load handling device whose power source was replaced, and / or the second and / or third and / or fourth load handling device, or a different load handling device.

[0083] fire suppression Some power sources may pose a fire hazard if exposed to mechanical damage or high temperatures. For example, power source 50 may be a lithium-ion battery with a normal operating temperature of, for example, less than 60° C. If the temperature exceeds the normal operating temperature, for example due to a short circuit, there is a risk that the temperature of the battery will continue to rise, and if the temperature of the battery exceeds a thermal runaway threshold temperature (e.g., 130° C.), the temperature may increase rapidly. Thermal runaway is a type of uncontrolled positive feedback and occurs in situations where an increase in temperature changes conditions in a way that causes a further increase in temperature. In the case of a lithium-ion battery, mechanical damage or a short circuit can result in an uncontrolled exothermic reaction that releases large amounts of heat.

[0084] The initial rise in temperature can be caused, for example, by a short circuit, mechanical damage, manufacturing defects, or heat from another source (e.g., charging, or other components in the load handling device). When the separator between the cathode and anode is worn or damaged by heat, a short circuit occurs, allowing a large current to flow directly between the anode and cathode, generating heat. At the onset of thermal runaway, the battery heats up to very high temperatures in a matter of seconds, causing the electrolyte to decompose and release flammable and toxic gases. Mechanical damage can also result in the release of electrolyte. The electrodes then begin to decompose via exothermic chemical reactions, further accelerating the thermal runaway process. Combustion occurs when the flammable electrolyte gases react with oxygen in the presence of heat.

[0085] With lithium-ion batteries, there can be several minutes between the initial rise in temperature and thermal runaway. This time can be used to safely contain the battery and prevent the fire from spreading to other parts of the system.

[0086] 14 is a flow chart illustrating a method for replacing a power supply 50 in a load handling device 31 in the particular event that the power supply 50 has overheated. An overheated power supply may be a power supply that has exceeded a predetermined threshold temperature, for example, at or slightly above the maximum operating temperature of the power supply. The illustrated method is an automated process which has the advantage that an overheated power supply can be safely and automatically contained.

[0087] In step 90, the overheating power source sends a warning or error signal to the load handling device. For example, the temperature of the power source installed in the load handling device may be monitored and a signal sent when the temperature exceeds a predetermined threshold temperature. For example, a lithium ion battery may have a normal operating range up to 60° C. and a predetermined threshold temperature of 65° C., and if the battery temperature exceeds 65° C., the battery management system sends a warning signal to the load handling device. In another example, the voltage of the power source may be monitored and a signal sent when the temperature exceeds a predetermined threshold temperature. The monitoring may be done by a control system with sensors on the load handling device, either integrated into the power source (e.g., a battery management system) or a separate system on the load handling device. The temperature and / or voltage and / or other characteristics of the power source in the load handling device may be continuously monitored during operation.

[0088] In step 91, the load handling device sends a warning or error signal to a control system. As described below, one or more control systems may be provided to perform functions including controlling movement of the load handling device on the track system. The warning or error signal informs the control system that the power supply is overheating.

[0089] In step 92, in response to a warning or error signal from the load handling device, the control system commands the load handling device to move to a picking means, i.e., to a location on the track system where the power supply can be swapped. In examples where the swapping operation is performed by a robot on the track system, the control system may command the load handling device to move to a grid cell near or adjacent to the robot. In examples where the swapping operation is performed by a power supply swapping station, the control system may command the load handling device to move to a grid cell near or adjacent to the power supply swapping station.

[0090] In step 93, the control system commands the picking means to place the overheated power source into a fire suppression container that safely contains the overheated power source and, if the power source catches fire, the fire suppression container acts to suppress and safely contain the fire. In some examples, the fire suppression container may be equipped with sensors to monitor the condition of the overheating power supply (eg, a temperature sensor to monitor the temperature).

[0091] In some examples, the picking vehicle can cover the fire suppression container with a fire resistant lid or blanket, which helps to further suppress and contain the fire. One or more fire resistant lids or blankets can be stored within reach of the picking vehicle, for example, next to the robot base, or in an adjacent grid cell on the track system, or at a power exchange station.

[0092] In step 94, the control system determines whether the overheated power supply can be safely handled, e.g., whether the temperature has dropped within the normal operating range of the power supply. For example, the temperature of the overheated power supply may be compared to a second predetermined threshold temperature. The second predetermined threshold temperature may be the same as the predetermined threshold temperature or may be different. For example, the predetermined threshold temperature may be a temperature slightly higher than the maximum normal operating temperature of the power supply and the second predetermined threshold temperature may be the ambient temperature.

[0093] If, in step 95, the overheating power supply cannot be safely handled, for example if the temperature exceeds a second predetermined threshold temperature, then the previous step 94 is repeated and the power supply continues to be monitored.

[0094] In step 96, if the overheating power source is handled safely, for example if the temperature drops below a second predetermined threshold temperature, the fire suppression container sends a signal to the control system indicating it is safe to retrieve the overheating power source.

[0095] In step 97, the fire suppression container containing the overheated power supply can be removed from the system, and the overheated power supply can then be removed from the fire suppression container and safely disposed of. For example, the second load handling device can move to the grid cell in which the fire suppression container is located, lift the fire suppression container into its container receiving space, and remove the fire suppression container. In an example where the fire suppression container is located at the power supply exchange station, the fire suppression container can be removed from the rear of the power supply exchange station.

[0096] The fire suppression container houses fire suppression materials, e.g., granular materials such as glass beads, perlite, vermiculite, etc., to suppress a fire. When the power source catches fire, the fire suppression material melts and absorbs heat from the power source, thereby providing a cooling effect that aids in extinguishing the fire. The molten fire suppression material also forms an impermeable layer around the power source, thus preventing oxygen from the air from reaching the power source, which also aids in extinguishing the fire. The advantage of using granular materials is that the material is densely packed and has a large surface area, which allows the fire suppression material to closely surround the overheating power source and melt quickly. Additionally, the fire suppression material may be porous, and its porosity, combined with its large surface area, makes it effective at absorbing liquids.

[0097] The melting point of the fire suppression material may be higher than the thermal runaway threshold temperature but lower than the temperature of the fire. Thus, the fire suppression material will only melt in the event of a thermal runaway to form an impermeable layer surrounding the overheating power source, which will automatically deploy in the event of a fire. If the overheating power source cools naturally before reaching the thermal runaway threshold temperature, the fire suppression material will not melt and can be reused.

[0098] The fire suppression material may have a high specific heat capacity to provide cooling to the power source as the fire suppression material heats up. The fire suppression material may have a high specific latent heat of melting to provide cooling to the power source during a phase transition as the fire suppression material melts.

[0099] 15(a)-(c) show schematic diagrams of a fire suppression container 100 partially filled with granular fire suppression material 102. In FIG. 15(a), the fire suppression container 100 is ready to receive an overheated power source (e.g., a power source that has exceeded a predetermined threshold temperature). In FIG. 15(b), an overheated power source 104 is placed within the fire suppression container 100. If the overheated power source 104 does not exceed a thermal runaway threshold temperature, the overheated power source 104 cools. Once the overheated power source 104 has sufficiently cooled (e.g., dropped below a second predetermined threshold temperature or returned to its normal operating temperature), the fire suppression container 100 may be removed from the lattice framework structure or from the power source exchange station.

[0100] If the overheating power source 104 exceeds the thermal runaway threshold temperature, the temperature of the overheating power source 104 will rise rapidly until a fire begins. As shown in FIG. 15(c), the fire suppression material 102 melts and forms an impermeable layer 106 surrounding the overheating power source 104. The fire is extinguished by the combined effect of cooling by the fire suppression material 102 and the impermeable layer preventing oxygen from reaching the overheating power source 104. Again, once the overheating power source returns to its normal operating temperature, the fire suppression container 100 can be removed. The overheating power source 104 can then be safely disposed of.

[0101] FIG. 16(a-d) show a schematic of a fire suppression container 100 partially filled with granular fire suppression material 102 contained in a pouch 108. The advantage of the pouch is that the fire suppression agent 102 is contained and the risk of spillage is reduced. In FIG. 16(a), the fire suppression container 100 is ready to receive a heat source. One or more pouches 108 containing the fire suppression material are placed inside the fire suppression container. In FIG. 16(b), a heat source 104 is placed within the fire suppression container 100. The heat source 104 is supported on and surrounded by the pouch 108. In FIG. 16(c), the heat source is experiencing thermal runaway and the material of the pouch 108 in contact with the heat source 104 begins to melt or burn, thus releasing the fire suppression material 102 from the pouch 108. 16(d), the fire suppression material 102 melts and forms an impermeable layer 106 that surrounds the overheated power source 104. The fire is extinguished by the combined effect of the cooling provided by the fire suppression material 102 and the impermeable layer preventing oxygen from reaching the overheated power source 104.

[0102] In some examples, the picking vehicle can cover the fire suppression container with a fire-resistant lid or blanket. This helps to further suppress and contain the fire. One or more fire-resistant lids or blankets can be stored within reach of the picking vehicle, for example, next to the robot base, or in adjacent grid cells on the track system, or at a power supply exchange station. In response to detecting that the power supply is overheating, the control system can automatically command a load handling device containing the overheated power supply to move to the picking vehicle, and then command the picking vehicle to place the overheated power supply in the fire suppression container, pick up the fire-resistant lid or blanket, and place the fire-resistant lid or blanket on top of the fire suppression container. In some cases, the fire-resistant lid or blanket can have a sealing means, for example, the fire-resistant lid can have a clasp or magnet to seal the lid to the fire suppression container.

[0103] In some examples, the fire suppression container may be lined with a fire blanket or other fire suppression material, such as fire resistant foam, as an alternative to or in addition to the granular fire suppression material.

[0104] Robot Arm 8 is a perspective view of a robotic arm according to an embodiment of the present invention. Robot 70 comprises a robot base 72 and a robot arm 74 terminating in an end effector 76 for holding a power source.

[0105] To provide multiple degrees of freedom of movement of the robot arm 74, and thus the end effector 76, the robot arm 74 comprises multiple moveable segments connected to each other by multiple pivotable joints, each of which provides rotation of the segment about one or more predefined axes of rotation, such as rotation about an axis along the arm (roll joint) and rotation about an axis across the arm (pitch joint). In a particular embodiment of the invention shown in FIG. 8, the robot arm 74 comprises an upper segment and a lower segment pivotally connected to each other by a robot elbow 78, providing both a roll joint and a pitch joint between the lower and upper segments. The end effector 76 is rotatably connected to a distal end of the upper segment of the robot arm 74 to define a robot wrist 80. The robot wrist 80 provides rotation about an axis along the upper segment of the robot arm 74 and across the robot arm 74. The pivotable joints connecting the upper and lower segments of the robot arm and the robot wrist connecting the end effector 76 provide six degrees of freedom of movement of the end effector 76. This allows the robot 70 to precisely position the end effector 76 to engage the power source 50 .

[0106] 8, the robot base 72 is mounted to horizontal support beams 82. Each of the horizontal support beams 82 is provided with a bracket 84 to enable the robot base to be mounted to a third lattice cell 14c of the lattice framework structure 1.

[0107] The movement of the robotic arm and end effector is performed by a control system including a processor and data storage means containing computer executable instructions that are executed by the processor to cause movement of the robotic arm and / or end effector.

[0108] Robot arm position FIG. 9 is a perspective view of the robot 70 of FIG. 8 attached to the third lattice cell 14c of the lattice framework structure 1. In the illustrated example, the robot 70 occupies the center cell (third lattice cell 14c) of the illustrated 3×3 lattice of cells, and thus the robot arm 72 can reach any of the eight adjacent lattice cells. All of the adjacent lattice cells are occupied by storage containers, two of which are used to store power sources 50. These two storage containers occupy the first and second lattice cells 14a, 14b. The end effector 76 of the robot 70 can insert the power source 50 into the storage container 50 in the adjacent cell, or remove the power source 50 from the storage container 50 in the adjacent cell. In other examples, the robot arm 72 may be able to reach further to access lattice cells that are not adjacent to the third lattice cell 14c to which the robot base 72 is attached. Although only the top level or layer of the lattice framework structure 1 is visible in the figure, it is understood that the lattice framework structure may be several layers deep. The visible storage container may be the top storage container 9 of a stack 11 of storage containers arranged in a storage column 10 below the grid cell.

[0109] In the illustrated example, the robot base 72 is mounted to the third lattice cell 14b. The horizontal support beams 82 are supported by the track system 13 of the lattice framework structure. Each of the four horizontal support beams 82 is supported by one of the four edges of the third lattice cell 14c, and each of the brackets 84 of the horizontal support beams is hooked around and under the horizontal members 5, 7 that support the track system. Mounting the robot base 72 to the lattice cells provides stability benefits for the robot 70. In the illustrated example, the footprint of the robot base 72 is entirely within one lattice cell, thus maximizing storage space.

[0110] Figure 10 shows the robot 70 of Figure 9 in a different position. The pivotable joint configuration of the robot 70 allows the robot 70 to reach into a storage container in any adjacent grid cell.

[0111] Load Handling Devices 11 is a perspective view of the load handling device 31 and robot 70 on the lattice framework structure 1. The load handling device 31 can access the robot 70 by moving laterally on the track system to adjacent or nearby grid cells. In the example shown, the load handling device 31 is located on a grid cell diagonally adjacent to the third grid cell 14c on which the robot base 72 is mounted. The robot arm 74 can reach both the load handling device 31 and a storage container 9 housing a power source 50 in another diagonally adjacent grid cell.

[0112] When there are several load handling devices requiring a power supply replacement, there is enough space around the robot 70 for several load handling devices to approach and occupy adjacent grid cells. This improves the efficiency of the power supply replacement process because the next load handling device in the queue for replacement is in a predetermined position and ready while the replacement operation is being performed on the previous load handling device in the queue. The robot 70 does not have to wait for the next load handling device to approach before beginning the power supply replacement operation. This makes the most efficient use of the robot 70, which is the limiting factor for the speed at which power supplies can be replaced.

[0113] FIG. 12 is a perspective view of a load handling device and a robotic arm mounted in a lattice cell of a lattice framework structure. The dashed box represents a power source and indicates two possible points where the power source enters the load handling device. The power source may be inserted or removed from the load handling device horizontally or vertically. To facilitate the insertion or removal of the power source, an aperture may be provided on the top or one or more sides of the body of the load handling device. In some examples, guides or rails may be provided to position the power source as it enters or exits the load handling device.

[0114] End effector The end effector 76 can take different forms, for example, a suction cup, a gripper, or a clamping device. The end effector shown in Figures 8 to 12 is a suction cup that is placed on top or on the side of the power source and can be activated to exert a suction force on the suction cup that holds the power source. The robotic arm 74 can then move the power source to the required position and the suction force is stopped to release the power source.

[0115] A suction cup is not the only option, and any end effector capable of manipulating the power source is applicable in the present invention. In examples where the end effector is a gripper or clamping device, the power source may have features (e.g., holes or recesses or rims) that cooperate with the end effector. In some cases, the power source may be provided with a case or cover, which may have features that cooperate with the end effector.

[0116] FIG. 13 is a perspective view showing a robot arm having an end effector 76 comprising a clamping or gripper device. The clamping device can function as an end effector 76 coupled to a robot arm 74 of a robot 70 as shown in FIG. 13. The clamping device is attached to the robot arm 74 to form the end effector 76. Movement of the robot arm 74 and the clamping device is controlled by a control system. The control system is configured to control the movement of the robot arm 74 and thus the movement of the end effector 76 such that a pair of clamps of the clamping device are positioned to clamp opposing walls of the power supply 50. One or more pressure sensors can be attached to the clamps to provide a signal to the control system of the engagement of the power supply with the walls. Once clamped, the control system can cause the robot arm 74 to lift the power supply from the load handling device.

[0117] Power exchange operation This section provides a detailed description of how the robot 70 performs a method for replacing a power supply 50 in a load handling device 31. The steps of the method are shown diagrammatically in Figures 6 and 7. Movement of the robotic arm and / or end effector of the robot 70 is commanded by a control system having a memory and a processor that store computer-executable instructions. The computer-executable instructions, when executed by the processor, provide instructions to the robot.

[0118] The robot base 72 of the robot 70 is attached to the third lattice cell 14c of the lattice framework structure 1. This provides stability to the robot 70 and allows the end effector 76 of the robot arm 74 to remove the first power source 50a from the load handling device 31 and replace it with the second power source 50b. The replacement is performed on the track system of the lattice framework structure, so there is no need to transport the load handling device 31 to a charging station or a replacement station. The first power source 50a here may represent a consumable power source and the second power source 50b may represent a fully charged power source.

[0119] The first step 60 is to command movement of the robot arm 74 by the control system such that an end effector 76 coupled to the robot arm 74 engages the first power source 50a installed in the load handling device 31. The end effector may engage, for example, by suction or clamping or gripping either the first power source 50a itself or a cover or case of the first power source. Once the end effector 76 has engaged the first power source 50a, the robot arm 74 is commanded to remove the first power source from the load handling device 31. Removal of the first power source from the load handling device 31 may simply be a vertical and / or lateral movement of the robot arm.

[0120] In a second step 62, the robotic arm 74 then moves into the first grid cell 14a with the first storage container 9a. The robotic arm 74 may then place the first power source 50a into the first storage container 9a within the first grid cell 14a. The end effector 76 is then commanded to disengage from the first power source 50a.

[0121] In a third step 64, the robotic arm 74 is commanded to move to the second grid cell 14b such that the end effector 76 enters the second storage container 9b in the second grid cell 14b. The end effector 76 engages the second power source 50b in the second storage container 9b, picks up the second power source 50b, and removes it from the second storage container 9b in the second grid cell 14b.

[0122] In a fourth step 66, the robotic arm 74 may then be commanded to approach the load handling device 31 and insert the second power source 50b into the load handling device. The end effector 76 then disengages from the second power source 50b.

[0123] A camera (not shown) may be attached to the robotic arm 74 to view the area in which the end effector 76 operates. The camera may include any suitable one or more cameras, such as one or more infrared cameras, and may include a three-dimensional depth camera. The camera may include lighting elements to illuminate the interior of the grid cells when inserting or removing a power source. Images from the camera are fed to a control system where the images are processed to aid in identifying and / or picking up and / or positioning the power source within the storage container. For example, the camera may identify an area of ​​the storage container that has space for the end effector to move within the storage container and position itself to allow it to pick up a power source. A camera attached to the robotic arm or end effector to guide and position the end effector may function as an alignment mechanism.

[0124] Fixing mechanism The load handling device 31 may include a securing mechanism for securing the power source 50 within the load handling device. The securing mechanism is used to hold the power source 50 within the load handling device 31 as the load handling device 31 moves on the track system 13. The securing mechanism may include any suitable mechanism known in the art, for example, a securing pin or a gripper.

[0125] In some examples, the securing mechanism can provide an electrical coupling between the power source and the drive mechanism 38. This has the advantage of a simpler structure with fewer parts. Instead of two separate systems for securing the power source 50 and for electrically coupling the power source 50, one system can perform both functions.

[0126] Power Switching Station In the above examples, the power exchange takes place on the track system, but in other examples, the power exchange can be performed at a dedicated power exchange station. For example, one or more power exchange stations can be located at the edge of the lattice framework structure adjacent to the track system 13, rather than on the track system 13 itself as in the previous examples. The power exchange stations can be located on a platform or mezzanine adjacent to the track system 13. In this case, instead of the first and second storage containers and the fire suppression container being standard storage containers of the type used for storing goods or items in a lattice framework structure, the first and second storage containers and the fire suppression container can be dedicated containers that do not occupy lattice cells of the track system, but are located on a platform at or near the power exchange station.

[0127] For example, FIG. 17 illustrates an exemplary power supply exchange station 110 in the form of a robot 70 located on a platform 112 adjacent the periphery of a portion of the track system 13. The robot 70 includes a robot base 72, a robot arm 74, and an end effector 76 at the end of the robot arm. The robot base 72 is fixed relative to the track system 13 by being mounted on the platform 112. The illustrated end effector 76 is in the form of a gripper for physically grasping the power supply 50, however, the end effector 76 may take any form suitable for releasably holding the power supply 50. The end effector 76 includes a pair of gripping members selectively movable between a gripping position for holding the power supply 50 and a release position for releasing the power supply 50. The robot base 72 and the end effector 76 are connected by a series of linkages and joints 78, 80. The joints are configured to provide the desired degrees of freedom to the robotic arm 74 to enable the robotic arm 74 to remove a power source 50 from a power supply compartment in the load handling device 31 and place it in the designated area 114, and / or pick up a replacement power source 50 from the designated area 114 and insert it into the power supply compartment. In this illustrated example, the robotic arm 74 is a six-axis robotic arm (i.e., the joints provide six degrees of freedom), which allows for relatively complex movements that provide flexibility with respect to relative positioning between the load handling device 31, the robotic arm 74, and the designated area 114.

[0128] The robot 70 is configured to replace the power supply 50 of the load handling device 31 located on a designated grid cell 14 adjacent to the robot 70. Depending on the size and configuration of the robot 70, the robot 70 may be configured to interact with the load handling device 31 on any one of a number of designated grid cells 14 in the vicinity of the robot 70. In other words, the end effector 76 of the robot arm 74 may be movable to the power supply compartments of at least two load handling devices 31 in the vicinity of the robot arm 74, as shown in FIG. 17. This allows the robot arm 74 to continue the power supply replacement even if the load handling device 31 fails and occupies one of the designated grid cells 14.

[0129] 17, the robot 70 removes a first power source 50a from the power source section of the load handling device 31 and stores it in a first storage container 9a in the designated area 114, and then picks up a second power source 50b from a second storage container 9b in the designated area 114 and inserts it into the power source section of the load handling device 31. In addition to the first and second storage containers 9a, 9b, a fire suppression container 100 is placed in the designated area 114 of the power source exchange station 110.

[0130] 18 illustrates an exemplary power supply exchange station 110 having power supply holders 116 disposed on a horizontal surface within a storage structure 118. In this example, each power supply holder 116 includes a top opening on a top surface of the storage structure 118 to allow each power supply holder 116 to removably receive a power supply 50. The area within the storage structure 118 below the power supply holders 116 may be used to house a power supply charging device for charging the power supply 50 when the power supply 50 is received within the power supply holder 116.

[0131] The power supply holder 116 of the power supply exchange station 110 described above is optionally accessible from the rear side of the power supply exchange station 110 to allow the power supply 50 to be inserted into or removed from the power supply holder 116 from the rear side of the power supply station 110. The rear side is defined as the side of the power supply exchange station 110 facing away from the track system 13. The rear side of the power supply exchange station 110 may face a maintenance area accessible to a human worker. This configuration allows the power supply 50 to be removed from the power supply exchange station 110 by a human worker (e.g., for maintenance) without the worker having to be located in an area with potentially dangerous equipment (e.g., the track system 13, the load handling device 31, the robot 70, etc.) or having to shut down the potentially dangerous equipment.

[0132] In the example shown in FIG. 18, the first and second storage containers are power supply holders 116 in a storage structure 118 of the power supply exchange station 110. In use, the robot 70 removes a first power supply from a power supply compartment of a load handling device (not shown) and places it in a first storage container of the storage structure 118, then removes a second power supply from a second storage container of the storage structure 118 and inserts the second power supply into the power supply compartment of the load handling device. The power supply exchange station 110a also includes a fire suppression container 100, which in this example is located at the rear of the storage structure 118. If a power supply in the load handling device is overheating, the load handling device travels to the power supply exchange station 110 and the robot 70 removes the overheated power supply from the load handling device and places the overheated power supply in the fire suppression container 100. After the overheated power supply has cooled and can be safely handled, the fire suppression container 100 can be easily removed from the rear of the power supply exchange station 110 and transported to a maintenance area.

[0133] The location of the power supply exchange station 110 described above is not limited to being adjacent the periphery of the track system 13. The power supply exchange station 110 may be located in any other suitable location accessible by the end effector of the robotic arm, such as on the track system 13 itself.

[0134] In some examples, the robot 70 may be mounted on the power supply exchange station 110 itself. For example, FIG. 18 shows a robot 70 having an articulated robot arm 74 mounted on the top surface of a storage structure 118 of the power supply exchange station 110. This power supply exchange station 110 may be located adjacent the periphery of the track system 13 such that an end effector of the robot arm 74 can transfer power supplies 50 between a power supply holder 116 and a load handling device 31 located on a designated grid cell 14 adjacent the power supply exchange station 110. Instead of an articulated robot arm 74, a robot arm 74 in the form of a gantry or Cartesian robot may be mounted on the power supply exchange station 110.

[0135] In some examples, each power supply exchange station 110 may be associated with multiple robots 70. In other words, multiple robots 70 may be configured to transfer power supplies 50 to and from the same power supply exchange station 110. For example, multiple robotic arms 74 may be mounted on or near a single power supply exchange station 110 to allow power supplies 50 for multiple load handling devices 31 to be replaced at a single power supply exchange station 110 during the same or overlapping time periods.

[0136] Where the power source 50 is a rechargeable power source, the power source holder 116 of the power source exchange station 110 described above preferably comprises a power source charging means for charging the power source 50 when received within the holder. For example, the power source holder 116 may include an electrical connector (not shown) configured to mate with an electrical connector of the power source 50, together with an external power source (e.g., mains power) and other electrical equipment (e.g., transformers, converters, etc.), to enable the external power source to charge the power source 50 when the power source 50 is received in the power source holder 116.

[0137] Control System One or more control systems may be provided to perform functions including, but not limited to, controlling the movement of the load handling devices on the track system, tracking the charge levels of the power sources, instructing the robotic arms when to replace power sources, tracking the number and charge levels of power sources stored in storage containers, controlling when and how storage containers are removed from the lattice framework structure, controlling the movement of the robotic arms and end effectors, and, if applicable, controlling the movement of the fixtures and robotic wheel base. These operations may be performed by the same control system or by different control systems.

[0138] Storage Container The first and second storage containers 9a, 9b may be the same as other storage containers 9 within the lattice framework structure 1 used to store products, or the first and second storage containers 9a, 9b may be dedicated storage containers adapted or configured for storing power sources 50.

[0139] The first and second storage containers 9a, 9b can be configured to house one power source or multiple power sources. In the example shown in Figures 9 to 12, one storage container is configured to house up to 12 power sources arranged in a 4x3 grid. Other configurations are also possible.

[0140] The first and second storage containers may include one or more compartments for holding one or more power sources. In some examples, the compartments may be formed by separators. In some examples, the first and second storage containers may be fire resistant.

[0141] power technology Examples of power sources include, but are not limited to, a lithium ion battery, a lithium ion polymer battery, a lithium air battery, a lithium iron battery, a lithium iron phosphate battery, a lead acid battery, a nickel cadmium battery, a nickel metal hydride battery, a nickel zinc battery, a sodium ion battery, a sodium air battery, a thin film battery, a smart battery, a carbon foam based lead acid battery, a capacitor, a supercapacitor, an ultracapacitor, a lithium capacitor, an electrochemical double layer capacitor, an electric double layer capacitor, a pseudocapacitor, or a hybrid capacitor.

[0142] definition In this document, the phrase "movement in the n-direction", where n is one of x, y, and z (and related phrases) is intended to mean movement substantially along or parallel to the n-axis, in either direction (i.e., toward the positive end of the n-axis or toward the negative end of the n-axis).

[0143] In this document, the term "connect" and its derivatives are intended to include the possibilities of direct and indirect connections. For example, "x is connected to y" is intended to include the possibilities of x being directly connected to y with no intervening components, and the possibilities of x being indirectly connected to y with one or more intervening components. Where a direct connection is intended, "directly connected," "directly connected," or similar terms are used. Similarly, the term "support" and its derivatives are intended to include the possibilities of direct contact and indirect contact.

[0144] For example, "x supports y" is intended to include the possibilities of x directly supporting and directly contacting y with no intervening components, and the possibilities of x indirectly supporting y with one or more intervening components that contact x and / or y. The term "attach" and its derivatives are intended to include the possibilities of direct and indirect attachment. For example, "x is attached to y" is intended to include the possibilities of x directly attached to y with no intervening components, and the possibilities of x indirectly attached to y with one or more intervening components.

[0145] As used herein, the term "comprises" and its derivatives are intended to have an inclusive, rather than exclusive, meaning. For example, "x comprises y" is intended to include the possibility that x includes one and only one y, multiple y, or one or more y and one or more other elements. When an exclusive meaning is intended, the phrase "x is composed of y" is used to mean that x includes only y and nothing else.

[0146] As used herein, the term "fully charged" as applied to a replaceable rechargeable power source means that the replaceable rechargeable power source is provided at its rated charge. In the case of a battery, this means that the battery voltage is at the rated voltage. The term "depleted" as applied to a replaceable rechargeable power source means that a predetermined residual charge remains in the replaceable rechargeable power source. In the case of a battery, this means that the battery voltage has dropped below the rated voltage to a pre-determined residual voltage.

Claims

1. 1. A method for replacing a power supply in a load handling device operable on a lattice framework structure, the method comprising: i) a track system 13 comprising a first set of tracks 17 extending in a first direction and grid members 19 of a second set of tracks extending in a second direction, said second direction being substantially perpendicular to said first direction, said track system 13 extending in a substantially horizontal plane and forming a grid pattern comprising a plurality of grid cells 14; ii) a number of uprights 3 supporting said track system 13; iii) a plurality of stacks 11 of storage containers 9 arranged in a plurality of storage columns 10 located below said track system 13; The method comprises: a) removing a first power source 50a from said load handling device 31; b) inserting a first power source 50a into a first storage container 9a in a first grid cell 14a; c) removing the second power source 50b from the second storage container 9b in the second grid cell 14b; d) inserting a second power source 50b into the load handling device 31.

2. 2. The method of claim 1, further comprising the step of instructing a second load handling device 31 to remove the first storage container 9a housing the first power source 50a from the first grid cell 14a, and optionally, the second load handling device 31 is the load handling device 31.

3. The method of claim 2, further comprising the step of instructing a third load handling device 31 to place an empty storage container 9 in the first grid cell 14a, and optionally, the third load handling device 31 is the load handling device 31.

4. 4. The method of claim 2 or 3, further comprising the step of charging the first power source 50a after the first storage container 9a is removed from the first grid cell 14a.

5. The method according to any one of claims 1 to 4, further comprising the step of instructing a fourth load handling device 31 to remove the second storage container 9b from the second grid cell 14b, optionally the fourth load handling device 31 being the load handling device 31.

6. The method of claim 5, further comprising the step of instructing a fifth load handling device 31 to place one or more power sources 50 containing storage containers 9 within the second grid cell 14b, and optionally, the fifth load handling device 31 is the load handling device 31.

7. The method of any one of claims 1 to 6, wherein the load handling device (31) comprises a securing mechanism configured to releasably secure a power source (50) within the load handling device (31).

8. The method of any one of claims 1 to 7, wherein the load handling device (31) is provided with an auxiliary power source.

9. 9. The method according to any one of the preceding claims, wherein the first and / or second storage container (9a, 9b) comprises one or more compartments configured to accommodate a power source (50).

10. 10. The method of any one of claims 1 to 9, wherein the first storage container (9a) comprises a fire suppression container (100) comprising fire suppression material (102) for safely containing an overheated power source (104).

11. A system for replacing a power source 50 in a load handling device 31 on a lattice framework structure 1, comprising: i) a lattice framework structure comprising a track system 13 comprising a first set of tracks 17 extending in a first direction and a second set of tracks 19 extending in a second direction, said second direction being substantially perpendicular to said first direction, said track system 13 extending in a substantially horizontal plane and forming a lattice pattern comprising a plurality of lattice cells 14; ii) a number of upright columns 3 supporting said track system 13; iii) a plurality of stacks 11 of storage containers 9 arranged in a plurality of storage columns 10 located below said track system 13; iv) a load handling device 31 comprising a first power source 50a for providing power for moving said load handling device 31 on said track system 13; v) a first storage container 9a in a first grid cell 14a; vi) a second storage container 9b housing a second power supply 50b for said load handling device 31, said second storage container 9b being located within a second grid cell 14b; vii) picking means configured to remove / insert the power source 50 into the load handling device 31.

12. The system according to claim 11, further comprising a control system configured to control the picking means to carry out the method according to any one of claims 1 to 10.

13. The system of claim 11 or 12, wherein the picking means comprises a robot 70 comprising a robot base 72 and a robot arm 74 coupled to the robot base 72, the robot base 72 being positioned on a third lattice cell 14c of the track system 13.

14. The system of claim 13 , wherein the robot base 72 is attached to the third lattice cell 14 c.

15. The system of claim 13 , wherein the robot base 72 comprises a wheel assembly and is configured to move on the track system 13 of the lattice framework structure 1 .

16. 16. The system of any one of claims 11 to 15, wherein the first container 9a is a fire suppression container 100 comprising fire suppression material 102 for safely containing an overheated power source 104.

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