Orbital Sensor Array

Abstract

The present invention provides an improved track sensor arrangement for an automated vehicle operating on an automated storage and retrieval system, the sensor being arranged to directly detect the position of the vehicle relative to an access opening. The term "directly detect" in the context of the present invention should be understood to mean that the gripping mechanism of the vehicle is precisely positioned relative to the access opening at the exact moment the sensor detects a particular structural feature of the track. In one aspect, the particular structural feature of the track is an intersection adjacent to the access opening.

Description

[Technical field]

[0001] FIELD OF THEINVENTION The present invention relates to remotely operated vehicles operating in conjunction with an automated storage and retrieval system, and more particularly to an arrangement including track sensors mounted on the automated vehicle for determining the vehicle's position on a grid-based track system of the automated storage and retrieval system. [Background technology]

[0002] Background and Prior Art FIG. 1 discloses a prior art automated storage and retrieval system 1 together with a framework structure 100, and FIGS. 2, 3 and 4 disclose three different prior art container transport vehicles 201, 301, 401 suitable for operating on such a system 1.

[0003] The framework structure 100 comprises upright members 102 arranged in rows to define storage compartments, which in turn comprise storage columns 105 arranged in rows between the upright members 102. In these storage columns 105, storage containers 106, also known as bins, are stacked one on top of the other to form stacks 107. The members 102 are typically made of metal, for example extruded aluminium profiles.

[0004] The framework structure 100 of the automated storage and retrieval system 1 comprises a rail system 108 arranged across the top of the framework structure 100, on which a plurality of container transport vehicles 201, 301, 401 can operate for raising and lowering the storage containers 106 from and to the storage columns 105, and for transporting the storage containers 106 up the storage columns 105. The rail system 108 comprises a first set of parallel rails 110 arranged to guide the movement of the container transport vehicles 201, 301, 401 in a first direction X across the top of the frame structure 100, as well as a second set of parallel rails 111 arranged orthogonal to the first set of parallel rails 110 for guiding the movement of the container transport vehicles 201, 301, 401 in a second direction Y orthogonal to the first direction X. The containers 106 stored in the columns 105 are accessed by the container transport vehicles 201, 301, 401 through access openings 112 in the rail system 108. The container transport vehicles 201, 301, 401 can move laterally above the storage columns 105, i.e. in a plane parallel to the horizontal XY plane.

[0005] The uprights 102 of the frame structure 100 can be used to guide the storage containers as they are raised from and lowered into the columns 105. The stacks 107 of containers 106 are typically free standing.

[0006] Each prior art container transport vehicle 201, 301, 401 comprises a vehicle body 201a, 301a, 401a and a first and second set of wheels 201b, 201c, 301b, 301c, 401b, 401c that respectively allow lateral movement of the container transport vehicle 201, 301, 401 in the X and Y directions. In Figures 2, 3 and 4 the two wheels of each set are fully visible. The first set of wheels 201b, 301b, 401b is arranged to engage two adjacent rails of the first set of rails 110 and the second set of wheels 201c, 301c, 401c is arranged to engage two adjacent rails of the second set of rails 111. At least one of the sets of wheels 201b, 201c, 301b, 301c, 401b, 401c can be raised and lowered so that the first set of wheels 201b, 301b, 401b and / or the second set of wheels 201c, 301c, 401c can engage with the corresponding set of rails 110, 111 at any time.

[0007] Each prior art container transport vehicle 201, 301, 401 also comprises a lifting device for vertical transport of the storage container 106, e.g. for lifting the storage container 106 from the storage column 105 and lowering the storage container 106 into the storage column 105. The lifting device comprises one or more gripping / engagement devices adapted to engage the storage container 106. These gripping / engagement devices can be lowered from the vehicle 201, 301, 401 so that the position of the gripping / engagement device relative to the vehicle 201, 301, 401 can be adjusted in a third direction Z, perpendicular to the first direction X and the second direction Y. Part of the gripping device of the container transport vehicle 301, 401 is shown in Fig. 3 and Fig. 4 with the reference numerals 304, 404. The gripping device of the container transport device 201 is not shown in Fig. 2 because it is arranged in the vehicle body 201a.

[0008] Conventionally, and for the purposes of this application, Z=1 identifies the topmost level where storage containers are available under the rails 110, 111, i.e., the level immediately below the rail system 108, Z=2 identifies the second level below the rail system 108, Z=3 identifies the third level, etc. In the exemplary prior art disclosed in FIG. 1, Z=8 identifies the lowest level, the bottommost level, of storage containers. Similarly, X=1...n and Y=1...n identify the location of each storage column 105 in the horizontal plane. Thus, using the Cartesian coordinate system X, Y, Z shown in FIG. 1 as an example, the storage container identified in FIG. 1 as 106' can be said to occupy storage location X=17, Y=1, Z=6. The container transport vehicles 201, 301, 401 can be said to travel in level Z=0, and each storage column 105 can be identified by its X and Y coordinates. Thus, the storage containers shown in FIG. 1 that extend above the rail system 108 can also be said to be arranged in layer Z=0.

[0009] The storage compartments of the framework structure 100 may be referred to as a grid 104, and the possible storage locations within this grid are referred to as storage cells. Each storage column may be identified by a location in the X and Y directions, and each storage cell may be identified by a container number in the X, Y, and Z directions.

[0010] Each prior art container transport vehicle 201, 301, 401 comprises a storage compartment or space for receiving and storing the storage containers 106 during transport across the rail system 108. This storage space may comprise a cavity arranged inside the vehicle body 201a, 401a, as shown in Figures 2 and 4 and described, for example, in International Patent Application Publication No. WO 2015 / 193278 and International Patent Application Publication No. WO 2019 / 206487, the contents of which are incorporated herein by reference.

[0011] 3 shows an alternative configuration of a cantilevered container transport vehicle 301. Such a vehicle is described in detail, for example, in Norwegian patent no. 317366, the contents of which are incorporated herein by reference.

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

[0013] Alternatively, the cavity container transport vehicle 401 may have a footprint that is larger than the lateral area defined by the storage column 105 as shown in Figures 1 and 4, as disclosed, for example, in International Patent Application Publication No. WO 2014 / 090684 or International Patent Application Publication No. WO 2019 / 206487.

[0014] As shown in FIG. 5, a rail system 108 typically comprises a rail 110 with a groove 501 along which the wheels of the vehicle travel. The groove 501 is defined by an upwardly projecting element 502. The groove 501 and the upwardly projecting element 502 are collectively known as tracks 503, and the upwardly projecting element 502 may alternatively be referred to as a "track wall" 502. Each rail may comprise one track, or each rail 110, 111 may comprise two parallel tracks. In other rail systems 108, each rail in one direction (e.g., X direction) may comprise one track, and each rail in the other orthogonal direction (e.g., Y direction) may comprise two tracks. Each rail 110, 111 may also comprise two track members fixed to each other, each track member providing one of the pair of tracks provided by each rail. As also shown in FIG. 5, orthogonal tracks 503 intersect to form an intersection 504 where there are no upwardly protruding elements 502 so that the wheels of the vehicle can cross the intersection in either the X or Y direction.

[0015] International Patent Application Publication No. WO 2018 / 146304, the contents of which are incorporated herein by reference, shows an exemplary configuration of rail system 108, with rails in both the X and Y directions and parallel tracks.

[0016] In the framework structure 100, most of the columns 105 are storage columns 105, i.e. columns 105 where the storage containers 106 are stored in the stacks 107. However, some columns 105 may have other purposes. In FIG. 1, columns 119 and 120 are dedicated columns used by container transport vehicles 201, 301, 401 to unload and / or receive the storage containers 106. Thereby, the storage containers 106 can be transported to an access station (not shown) where they can be accessed from outside the framework structure 100 or where the containers 106 can be transferred from or into the framework structure 100. In the art, such a place is usually called a "port" and the column where this port is located can be called the "port column" 119, 120. The transport to the access station can be in any orientation: horizontal, inclined and / or vertical. For example, storage containers 106 may be placed in random or dedicated columns 105 within the framework structure 100 and then picked up by any container transport vehicle and transported to port columns 119, 120 for further transport to an access station. Transport from the port to the access station may require movement along a variety of different directions by means such as delivery vehicles, trolleys, or other transport lines. Note that the term "inclined" refers to transport of storage containers 106 having an overall transport direction halfway between horizontal and vertical.

[0017] In FIG. 1 , the first port column 119 may be, for example, a dedicated loading / unloading port column where the container transport vehicles 201, 301, 401 can unload storage containers 106 to be transported to an access station or transfer station, and the second port column 120 may be a dedicated receiving port column where the container transport vehicles 201, 301, 401 can receive storage containers 106 transported from the access station or transfer station.

[0018] An access station may typically be a receiving or storage station where a product item is removed from or positioned in a storage container 106. At the receiving or storage station, the storage container 106 is not typically removed from the automated storage and retrieval system 1 but is accessed and then returned to the framework structure 100 again. A port may also be used to transfer a storage container to another storage facility (e.g. another framework structure or another automated storage and retrieval system), a transport vehicle (e.g. a train or lorry), or a production facility.

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

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

[0021] The conveyor system may be arranged to transport the storage containers 106 between the different framework structures, for example as described in International Patent Application No. 2014 / 075937, the contents of which are incorporated herein by reference.

[0022] 1, one of the container transport vehicles 201, 301, 401 is instructed to retrieve the target storage container 106 from its location and transport it to the unloading port column 119. This action involves moving the container transport vehicle 201, 301, 401 to a location above the storage column 105 where the target storage container 106 is positioned, retrieving the storage container 106 from the storage column 105 using a lifting device (not shown) of the container transport vehicle 201, 301, 401, and transporting the storage container 106 to the unloading port column 119. If the target storage container 106 is located deep within the stack section 107, i.e., one or more other storage containers 106 are positioned above the target storage container 106, this action also involves temporarily moving the storage container positioned above before lifting the target storage container 106 from the storage column 105. This step, sometimes referred to in the art as "digging", may then be performed by the same container transport vehicle used to transport the target storage container to the unloading port column 119, or may be performed by one or more other cooperating container transport vehicles. Alternatively, or in addition, the automated storage and retrieval system 1 may have container transport vehicles 201, 301, 401 dedicated to the task of temporarily removing the storage container 106 from the storage column 105. Once the target storage container 106 has been removed from the storage column 105, the temporarily removed storage container 106 may be repositioned in the original storage column 105. However, the removed storage container 106 may instead be relocated to another storage column 105.

[0023] When a storage container 106 is to be stored in one of the columns 105, one of the container transport vehicles 201, 301, 401 is directed to receive the storage container 106 from the receiving port column 120 and transport it to a location above the storage column 105 where it is to be stored. After a storage container 106 positioned at or above a target location in the stack section 107 is removed, the container transport vehicle 201, 301, 401 positions the storage container 106 in the desired location. The removed storage container 106 is then returned to the storage column 105 or relocated to another storage column 105.

[0024] To monitor and control the automated storage and retrieval system 1, for example, the location of each storage container 106 within the framework structure 100, the contents of each storage container 106, and the movements of the container transport vehicles 201, 301, 401 so that the container transport vehicles 201, 301, 401 can deliver the desired storage container 106 to the desired location at the desired time without colliding with each other, the automated storage and retrieval system 1 includes a control system 500 that is typically computerized and typically includes a database for tracking the storage containers 106.

[0025] Against this background, it would be desirable in the art to provide a container transport vehicle that combines the most beneficial characteristics of cantilevered vehicles and vehicles with internally arranged cavities.

[0026] Track Sensor It is desirable for the control system 500 to know the exact positioning of the above-mentioned container transport vehicles as they travel along and / or stop on the rail system 108. In particular, it is desirable for the container transport vehicles to be precisely positioned such that when a lifting or lowering operation is intended, the vehicle's lifting device is precisely aligned with respect to the access opening 112. Such an access opening is bounded by two intersecting sets of parallel tracks, creating four adjacent intersections 504 around the access opening.

[0027] It is known to arrange a sensor or sensors on a container transport vehicle that detects the position of the vehicle as it travels along or stops on a rail system. In particular, known sensors arranged on a vehicle of the type illustrated as vehicle 301 can detect when vehicle 301 encounters an intersection 504 of orthogonal tracks 503. Such a sensor has a single emitter and detector.

[0028] Due to the shape and configuration of the vehicle 301, the gripping device 304 is arranged on an extended cantilever, so that at the moment the sensor detects the adjacent intersection 504, the gripping device is not aligned over the target access opening. Rather, the sensor makes the detection as it passes the preceding intersection, and the control system 500 then "counts" a predetermined number of wheel revolutions as the vehicle travels further to determine that the gripping mechanism 304 is correctly positioned over the target access opening. Therefore, the structure of the track system, and in particular the sensor arrangement, which detects the intersections, is needed at the moment when the vehicle is positioned so that the gripping device is exactly over the target access opening. [Prior art documents] [Patent documents]

[0029] [Patent Document 1] International Publication No. 2015 / 193278 [Patent Document 2] International Publication No. 2019 / 206487 Summary of the Invention [Means for solving the problem]

[0030] Summary of the Invention The invention is set forth and characterized in the independent claims, while further characteristic features of the invention are set forth in the dependent claims.

[0031] The present invention provides an improved track sensor arrangement for an automated vehicle operating on an automated storage and retrieval system, where the sensor is arranged to directly detect the position of the vehicle relative to an access opening. The term "directly detect" in the context of the present invention should be understood to mean that the gripping mechanism of the vehicle is appropriately positioned relative to the access opening while the sensor simultaneously detects a particular structural feature of the track. In one aspect, the particular structural feature of the track is an intersection adjacent the access opening, and more specifically, the termination of the track wall at the intersection.

[0032] The present invention relates to a track sensor arranged on a container transport vehicle or other type of vehicle that is remotely operated to operate on a two-dimensional grid-based rail system of an automated storage and retrieval system. Such a vehicle may include a vehicle body, a first set of wheels that can move the remotely operated vehicle in a first direction on the rail system, and a second set of wheels that can move the remotely operated vehicle in a second direction on the rail system, the second direction being orthogonal to the first direction. Such a vehicle changes direction on the grid-based rail system by selectively raising or lowering the wheels in a maneuver known as a "track shift."

[0033] For purposes of this application, the terms "container transport vehicle," "remotely operated vehicle," and "autonomous vehicle" all refer to wheeled robotic vehicles that operate on a rail system aligned across the top of a framework structure that is part of an automated storage and retrieval system.

[0034] The term "storage container" as used herein defines a receptacle for storing goods. Alternative descriptive terms for such containers are "goods container", "goods holder", "goods container", "storage bin", etc. In this context, a storage container can be a bin, a tote box, a pallet, a tray, etc. Different types of goods holders can also be used in the same automated storage and retrieval system. The term "storage container" can, in some contexts, be considered to be analogous to an actual item that can be grasped, lifted and lowered by the system's vehicles, even if the item is not stored in a single container.

[0035] The relative terms "above", "below", "below", "on top", "higher" etc. shall be understood in their ordinary sense as viewed in a Cartesian coordinate system. When referring to a rail system, "above" or "on top" shall be understood as a position closer to the surface rail system (relative to other components) and conversely, the terms "below" or "below" shall be understood as a position further from the rail system (relative to other components).

[0036] In one aspect, the present invention provides a method for producing a method for treating a cancer cell comprising: an automated wheeled vehicle arranged to run along a grid-based rail system comprising a plurality of parallel rails arranged in a first direction and a plurality of parallel rails arranged in a second direction, the first and second directional rails intersecting perpendicularly to form a plurality of intersections defining a plurality of grid access openings, each rail being provided with either a single track for the wheels of the vehicle or a pair of parallel tracks, each track being in the form of a groove defined by upwardly projecting track walls that terminate at an end of the intersection, the vehicle being capable of changing its direction of run from the first direction to a second direction by alternately raising or lowering a set of wheels into and out of the track, the first set of wheels being arranged for run in the first direction and the second set of wheels being arranged for run in the second direction; b. a sensor mounted on the vehicle and arranged to be raised or lowered when the first wheel set is raised or lowered; Equipped with This sensor is i. a sensor body having a recess arranged to receive a track wall of the track when the first wheel set is lowered into the track; ii. a plurality of emitters, each arranged to emit a beam of energy, and one or more corresponding detectors arranged to detect the beam of energy from the emitters; Equipped with iii. the emitters and one or more corresponding detectors are arranged on opposite sides of the recess such that when the first wheel set is lowered into the track, a track wall blocks beams emitted from the emitters from reaching their corresponding detectors; iv. Additionally, sensors are mounted on the vehicle in positions such that the beams from the emitters can reach their corresponding detectors when a predetermined portion of the vehicle is positioned over the access opening of the target.

[0037] In another aspect, the present invention provides a method for producing a composition comprising: The present invention includes a method for determining the position of a motor vehicle operating on a grid-based rail system comprising a plurality of parallel rails arranged in a first direction, the first direction rails and a second direction rails intersecting perpendicularly to form a plurality of intersections defining a plurality of grid access openings, each rail being provided with either a single track for wheels of the vehicle or a pair of parallel tracks, each track being in the form of a groove defined by upwardly projecting track walls, the track walls terminating at an end of the intersection, the vehicle being capable of changing its direction of travel from the first direction to a second direction by alternately raising or lowering a set of wheels into and out of the track, the first set of wheels being arranged for travel in the first direction and the second set of wheels being arranged for travel in the second direction, the method comprising: a. providing a sensor, the sensor comprising: i. a sensor body having a recess arranged to receive a track wall of the track when the first wheel set is lowered into the track; ii. a plurality of emitters, each arranged to emit an energy beam, and one or more corresponding detectors arranged to detect the energy beams from the emitters; Equipped with iii. the emitters and corresponding detector or detectors are arranged on opposite sides of the recess such that when the first wheel set is lowered into the track, a track wall blocks beams emitted from the emitters from reaching their corresponding detectors; b. mounting a sensor on the vehicle in a location that allows a beam from an emitter to reach its corresponding detector while a predetermined portion of the vehicle is positioned over an access opening of the target; c. lowering a first wheel set of the vehicle onto the track to travel the vehicle in a first direction, the sensors also being lowered such that the track walls enter recesses and block beams from the emitters from reaching their corresponding detectors; d. driving the vehicle in a first direction until the beam from the emitter passes through a terminus of a track wall at an intersection adjacent an access opening of the target; e. stopping the vehicle when the sensor is positioned relative to an adjacent intersection such that a predetermined portion of the vehicle is aligned over the access opening of interest; The present invention is characterized by comprising:

[0038] In one aspect, the invention provides an arrangement including at least one track sensor mounted on an automated vehicle for detecting a position of the vehicle relative to a track of a rail system of an automated storage and retrieval system as the vehicle travels in a first direction. In one aspect, a plurality of sensors are arranged on the vehicle, at least one sensor arranged for detecting a position with respect to travel in a first direction and at least one sensor arranged for detecting a position with respect to travel in a second direction. Hereinafter, the arrangement will be described by referring to such one or more sensors in the singular (sensor / this sensor), although it will be understood that if the arrangement comprises multiple sensors, such description in the plural applies.

[0039] A sensor according to one aspect of the invention comprises a sensor body having a recess arranged longitudinally in the direction of travel of the vehicle. A plurality of emitters are arranged along one side of the recess, each emitter having a corresponding detector arranged on the opposite side of the recess. The term "corresponding detector" of an emitter should be understood to encompass an arrangement in which each emitter is associated with its own unique detector, as well as an arrangement in which one detector can detect beams from multiple emitters. In the latter case, multiple emitters will have the same detector as their "corresponding" detector. In another embodiment, the sensor body is "L" shaped, with the emitters arranged on the short leg of the "L" and the corresponding detectors arranged at or near the end of the long leg of the "L". The beams are projected obliquely upwards to the corresponding detector. In this embodiment, the space between the emitters and the detectors directly adjacent thereto can be considered similar to the "recess" described above.

[0040] The emitter emits a beam of energy in the form of an infrared signal, a light signal, or other suitable signal known in the art.

[0041] The emitters are arranged "successively" along the recess. In this context, the term "successively" means that as the vehicle travels in a given direction and the sensor passes a given location, the emitters encounter this location one after the other. The emitter that first encounters this location can be called the "leading" emitter and the subsequent emitters the "trailing" emitters.

[0042] The sensors are mounted on the vehicle such that they are raised out of or lowered into the track grooves as the associated wheel set is raised or lowered during a track shifting operation. To accomplish this coordinated raising and lowering, the sensors can be mounted on the wheel set, a moveable frame associated with the wheel set, the vehicle body, or other structure on the vehicle that rises or lowers in conjunction with the track shifting operation.

[0043] When a wheel set is lowered into contact with the rail, the sensor associated with that wheel set is lowered so that the track wall interrupts the straight line between the emitter and the corresponding detector. In one embodiment, the wall enters a recess in the sensor body, but in an embodiment with an L-shaped sensor body, the wall enters a recess between the emitter and the corresponding detector. Thus, the track wall will block the beam from the emitter from reaching the corresponding detector. When the wheel set is raised, the associated sensor is also raised out of the groove so that the track wall is not in the recess and the beam is not interrupted.

[0044] In one embodiment, the sensors of the present invention are arranged under the vehicle within the vehicle's periphery defined by the outer wall or end of the vehicle body and connected to the vehicle such that when a track shifting operation of the vehicle is initiated to configure the vehicle to run in a first direction, a first sensor associated with a first set of wheels is lowered to a position within the track groove. In the same operation, a second sensor associated with a second set of wheels is raised to a position above the track groove. Conversely, when a track shifting mechanism of the vehicle is initiated to configure the vehicle to run in a second direction, the second sensor is lowered to a position within the track groove and the first sensor is raised above the track groove.

[0045] The sensors communicate electronically with the control system of the automated storage and retrieval system, or alternatively, directly with the on-board control system of the vehicle itself. When the vehicle travels over a track section with a track wall, the beams from all emitters of the sensors in the groove are interrupted. As mentioned above, the track of the rail system has track walls between each intersection that bounds the access openings, so the control system knows that the vehicle is currently located between each access opening of the grid when all beams are interrupted. When the vehicle travels to a position where the track does not have a track wall, such as an intersection of orthogonal tracks, the beams are not interrupted and can reach the corresponding detector. Thanks to the sequential arrangement of the emitters, the beam from a leading emitter can reach the corresponding detector at the moment when the leading beam passes the end of the track wall, while the beam or beams from the trailing emitter remain interrupted. In this way, the leading sensor can instantly detect the end of the track wall. The sensor thereby directly detects the position of the vehicle relative to the end of the track wall, especially at the intersections. According to one aspect, the distance between the leading and trailing sensors corresponds to a tolerance for positioning of the vehicle relative to the access opening.

[0046] According to one embodiment, the sensor comprises a leading emitter, a first trailing emitter and a second trailing emitter. The sensor is arranged on the vehicle such that a gripping device of the vehicle is aligned over the access opening when the beam of the leading emitter is blocked from reaching its corresponding detector by a structure at an adjacent intersection, while the beams of the first and second trailing emitters reach their respective detectors. Furthermore, according to this embodiment, the emitters are arranged on the sensor such that the vehicle is misaligned with respect to the access opening of the target if any of the following conditions are met: a. the beam from the leading emitter and the beam from the first subsequent emitter are detected by corresponding detectors, while the beam from the second subsequent emitter is blocked from reaching the detector; or b. the beams from the leading emitter and the second subsequent emitter are detected by corresponding detectors while the beam from the first subsequent emitter is blocked; or c. The beams from all three emitters are detected by their corresponding detectors.

[0047] In use of this embodiment, the vehicle would be driven to an intersection adjacent the target access opening. As the sensor passes the end of the track wall, the beam from the leading emitter would be detected first while the beams from the first and second trailing emitters would remain blocked. As the vehicle proceeds, the leading beam and the first trailing beam would be detected while the second trailing beam would remain blocked. As the vehicle proceeds to its proper position, the leading beam would be blocked by the end of the next track wall at the intersection while the beams from the two trailing emitters would be detected since they are at the intersection. The placement of the emitters within the sensor body is such that any detect / block combination of beams other than "block-detect-block" would indicate improper alignment with the intersection.

[0048] Preferably, the sensor of the present invention is mounted on the vehicle in a position such that the gripping device of the vehicle is precisely aligned over the access opening when the sensor is properly positioned relative to the intersection structure. Thus, the exact mounting location of the sensor on the vehicle depends on the shape and size of the vehicle and the location of the gripping device on the vehicle.

[0049] In one embodiment, a vehicle of the present invention is configured as follows, although it should be understood that sensors of the present invention can be installed in other types of vehicles where space and configuration permits.

[0050] In one aspect, the sensor is connected to a remote-operated vehicle for transporting a storage container while operating on a two-dimensional rail system of an automated storage and retrieval system. The vehicle includes a vehicle body, a first wheel set enabling movement of the remote-operated vehicle in a first horizontal direction of the rail system, and a second wheel set enabling movement of the remote-operated vehicle in a second horizontal direction of the rail system, the second direction being perpendicular to the first direction. The vehicle body includes a motor section housing at least one drive motor, and a cavity section providing a cavity for housing the storage container, the remote-operated vehicle having a center of gravity disposed in the cavity section, the first wheel set including a pair of drive wheels and a pair of passive wheels. The pair of passive wheels are provided in the cavity section and transfer a share of the load from the remote-operated vehicle to the rail system while moving in the first horizontal direction, and the pair of passive wheels are arranged on the opposite side of the center of gravity to the pair of drive wheels of the first wheel set. [Brief description of the drawings]

[0051] In order to facilitate an understanding of the invention, the following drawings are included, which illustrate embodiments of the invention and are given by way of example only:

[0052] [Figure 1] FIG. 1 is a perspective view of a framework structure of a prior art automated storage and retrieval system.

[0053] [Diagram 2] FIG. 2 is a perspective view of a prior art container transport vehicle having cavities arranged therein for holding storage containers.

[0054] [Diagram 3] FIG. 3 is a perspective view of a prior art container transport vehicle having a cantilever for holding storage containers underneath.

[0055] [Figure 4]FIG. 4 is a perspective view from below of a prior art container transport vehicle having cavities arranged therein for holding storage containers.

[0056] [Diagram 5] FIG. 5 is a perspective view of a portion of a prior art rail system showing an intersection between orthogonal tracks.

[0057] [Figure 6] FIG. 6 is a side view of a remotely operated vehicle, according to one embodiment of the present invention.

[0058] [Figure 7] FIG. 7 is a side view of a remotely operated vehicle according to another embodiment of the present invention.

[0059] [Figure 8] FIG. 8 contextualizes the invention by illustrating two different scenarios in which a remotely operated vehicle is positioned on the rails of a framework structure according to an embodiment of the invention.

[0060] [Figure 9] FIG. 9 is a bottom view of the remote-controlled vehicle equipped with sensors.

[0061] [Figure 10] 10A and 10B are alternative embodiments of the sensor body.

[0062] [Figure 11] 11 and 12 show the sensor mounted on the underside of the remotely operated vehicle. [Figure 12] 11 and 12 show the sensor mounted on the underside of the remotely operated vehicle.

[0063] [Figure 13] 13 and 14 show the sensor lowered into the track groove. [Figure 14] 13 and 14 show the sensor lowered into the track groove.

[0064] [Figure 15] FIG. 15 shows an embodiment of the invention where the sensor is appropriately positioned relative to the intersection, with the vehicle not shown for clarity.

[0065] [Figure 16] FIG. 16 is a side perspective view of a detail of the sensor of FIG.

[0066] [Figure 17] 17 and 18 show the sensor entering the intersection but not yet progressing to the proper alignment position. [Figure 18] 17 and 18 show the sensor entering the intersection but not yet progressing to the proper alignment position.

[0067] [Figure 19] FIG. 19 shows the sensor advanced beyond the proper alignment position.

[0068] [Figure 20] FIG. 20 shows the sensor aligned with respect to the access opening of the subject. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0069] Detailed Description of the Invention In the following, embodiments of the invention will be described in more detail with reference to the accompanying drawings, in which it is understood, however, that each drawing is not intended to limit the invention to the subject matter shown in the drawing.

[0070] The framework structure 100 of the automated storage and retrieval system 1 is constructed in accordance with the prior art framework structure 100 described above in relation to Figures 1 to 5, i.e. a number of upright members 102, and the framework structure 100 also comprises a first, upper rail system 108 in the X and Y directions.

[0071] The framework structure 100 further comprises storage compartments in the form of storage columns 105 disposed between the members 102, within which storage containers 106 can be stacked in stacks 107.

[0072] The framework structure 100 can be of any size. In particular, it is understood that the framework structure can be significantly wider and / or longer and / or deeper than is disclosed in Figure 1. For example, the framework structure 100 can have a horizontal extent of more than 700x700 columns, as well as a depth of more than 12 containers.

[0073] As shown in FIG. 5, a rail system 108 typically includes rails 110 with grooves 501 along which the vehicle wheels travel. The grooves 501 are defined by upwardly projecting elements 502. The grooves 501 and upwardly projecting elements 502 are collectively known as tracks 503, and the upwardly projecting elements 502 may alternatively be referred to as "track walls" 502. Each rail may include one track, or each rail 110 may include two parallel tracks. In other rail systems 108, each rail in one direction (e.g., the X direction) may include one track, and each rail in the other orthogonal direction (e.g., the Y direction) may include two tracks. Each rail 110 may also include two track members fixed to each other, each track member providing one of the pair of tracks provided by each rail. 5, orthogonal tracks 503 intersect to form intersections 504 where there are no upwardly protruding elements 502 so that vehicle wheels can cross the intersection in either the X or Y direction. At intersection 504, track walls 502 terminate at termini 506.

[0074] Sensor Arrangements Associated with Various Vehicle Embodiments In one aspect, the sensor array of the present invention includes sensors 600 that can be connected to known remotely operated vehicles operating on a grid-based rail system of an automated storage and retrieval system, as described in the Background section above. In another aspect, the sensor array includes sensors 600 that are connected to an automated vehicle of the novel embodiment described below.

[0075] The remote-operated vehicle 50 of FIG. 6 is for transporting containers / goods holders while operating on the two-dimensional rail system of the automated storage and retrieval system shown in FIG. 1. The vehicle 50 comprises a vehicle body 10, a first set of wheels 12 that allows the remote-operated vehicle 50 to move in a first horizontal direction (e.g., X-direction) of the rail system, and a second set of wheels 14 that allows the rail system of the remote-operated vehicle 50 to move in a second horizontal direction (e.g., Y-direction). With reference to FIG. 1, the second direction (Y-direction) is perpendicular to the first direction (X-direction). The vehicle body 10 comprises a motor section 16 that houses at least one drive motor (shown in FIG. 6), and a cavity section 20 that provides a cavity 22 for housing the goods holders. As shown in FIG. 7, the center of gravity COG (not visible in FIG. 6) of the remote-operated vehicle 50 is located within the cavity section 20.

[0076] Returning to Fig. 6, the first wheel set 12 includes a pair of drive wheels 12D and a pair of passive wheels 12P. In the illustrated embodiment, the pair of passive wheels 12P are provided in the cavity portion 20. The passive wheels 12P transfer the load from the remote controlled vehicle 50 to the rail system when the remote controlled vehicle 50 described above is moving in the first horizontal direction. With reference to Figs. 6 and 7, the pair of passive wheels 12D is arranged on the opposite side of the center of gravity COG to the pair of drive wheels 12P.

[0077] Providing a pair of passive (non-driven) wheels 12P on the remotely operated vehicle 50 allows for a simplified and more robust vehicle design, which also allows for simpler maintenance procedures.

[0078] The vehicle design according to Fig. 6 also contributes to a significant weight reduction of the vehicle 50, since in this configuration no additional drive motors as well as motion transmission mechanisms are required. Furthermore, due to the reduced total weight of the vehicle 50, the vehicle has better acceleration characteristics. In relevant situations, the total kinetic energy of the moving vehicle 50 is significantly reduced. Therefore, in the event of an accidental collision involving another vehicle and / or a human operator in the rail system shown in Fig. 1, the consequences will be less severe.

[0079] 6, the cavity portion 20 includes an exterior wall 28 that forms a portion of the periphery of the remotely operated vehicle 50. The exterior wall 28 is flat and perpendicular to the horizontal (XY) plane of FIG.

[0080] Regarding the second wheel set 14, the second wheel set 14 is composed of a pair of wheels mounted on a structural cross member 30 in the vehicle body 10. In FIG. 6, the pair of wheels is a pair of drive wheels 14D. A motor 15 for driving the drive wheels 14D of the second wheel set 14 is also shown in FIG. 6. On the opposite side of the pair of drive wheels 14D, a pair of passive wheels 14P, which is the second wheel set 14, is arranged. As shown in FIG. 6, the pair of passive wheels 14P described above is arranged on the outer wall 28 of the remote control vehicle 50. The motor section 16 of the vehicle 50 is provided with a motor (not shown) for raising and lowering the second wheel set 14. In the art, raising and lowering a set of wheels to change the direction of movement of the container transport vehicle from the X direction to the Y direction in FIG. 1 or vice versa is known as "track shifting". A part of the track shifting mechanism 17 is also shown.

[0081] Figure 7 is a side view of a remotely operated vehicle 50 according to another embodiment of the invention. More precisely, in the embodiment of Figure 7, a different track shifting mechanism is employed, a part of which is shown in Figure 7.

[0082] As can be easily imagined, the footprint of the illustrated remotely operated vehicle 50 is rectangular, but the vehicle body 10 has an asymmetric shape in a plane extending in the YZ directions.

[0083] Returning to the first wheel set 12 (described in relation to FIG. 6), a pair of drive wheels 12D of the first wheel set 12 is provided on the motor section 16 of the remotely operated vehicle 50. The motor section 16 of the remotely operated vehicle 50 is also provided with axles (not visible in FIGS. 6-7) corresponding to the pair of drive wheels 12D of the first wheel set 12. The aforementioned motor section 16, which also holds the battery 26 of the remotely operated vehicle 50, is provided with a drive motor 18 for powering the drive wheels 12D. The motor section 16 and the cavity section 20 are arranged side by side. The pair of passive wheels 12P is arranged on the opposite side of the center of gravity COG to the pair of drive wheels 12D. The passive wheels 12P of the first wheel set 12 are not connected by an axle and rotate independently of each other. In this way, the individual wheels are separated, and wheel spin, which may occur for individual wheels of a wheel pair, is suppressed. A second set of wheels 14 (described more fully in connection with FIG. 6) is also shown.

[0084] On a general level, the presence of non-driven wheels reduces the risk that these wheels will start to spin as a result of traction loss between the wheels and the supporting rail.

[0085] 7, the distance D1 between the center of one of the driving wheels 12D of the first wheel set 12 and the associated corner 13D of the vehicle 50 is greater than the distance D2 between the center of one of the passive wheels 12P of the first wheel set 12 and the associated corner 13P of the vehicle 50. In the relevant situation, the two driving wheels 12D of the first wheel set are of the same size and the two passive wheels 12P of the first wheel set are of the same size. The two driving wheels 12P have a larger diameter than the two passive wheels 12P.

[0086] Providing smaller passive wheels 12P and larger driven wheels 12D means that the passive wheels 12P can be moved closer to the corners 13P of the vehicle, i.e. closer to the periphery of the vehicle, resulting in a more stable vehicle with passive wheels that are less prone to spinning.

[0087] FIG. 8 illustrates the invention in context by showing two different scenarios in which a remotely operated vehicle is positioned on the rails 108 of a framework structure.

[0088] As shown in Figure 8, the vehicle 50 is positioned above the storage column, directly adjacent to the roof support 32. Due to its design, the vehicle 50 is able to access the item holders stored in the storage column described above. More specifically, the cavity portion of the vehicle 50 (shown and described in relation to Figures 5-6) includes a peripheral outer wall 28 that faces the roof support 32. The outer wall 28 is flat and perpendicular to the horizontal (XY) plane. When the flat outer wall 28 of the vehicle 50 is very close to or abuts the roof support 32, the cavity portion is aligned with the storage column below such that the item holders can be extracted vertically by the remote operated vehicle 50.

[0089] The other remote operated vehicle 50 shown in Figure 8 is shown positioned adjacent to the protective fence 34 that defines the grid structure, at the edge of the grid structure. As described in relation to the first remote operated vehicle 50 of Figure 8, the exterior wall 28 of the vehicle 50 is flat and perpendicular to the horizontal (XY) plane, with the associated benefits discussed above, such as improved retrieval capability for difficult to access item holders.

[0090] A common feature of the two scenarios in Fig. 8 is that when raising or lowering an item holder from or into a storage column, the remotely operated vehicle 50 covers a single storage column across one horizontal direction of the rail system 108 and covers between a first and a second storage column across another horizontal direction of the rail system 108. For a given grid size, this relatively small vehicle footprint lends itself to the use of more remotely operated vehicles than was previously feasible. More specifically, two operating vehicles 50 can occupy adjacent grid positions such that in one horizontal direction, the flat outer wall 28 of one vehicle 50 faces the flat outer wall 28 of another vehicle 50.

[0091] Sensor Array While the sensor array is described in relation to mounting on the vehicle 50 as described above, it should be understood that the sensor can be mounted on vehicles of different configurations, provided that the size and shape of the sensor 600 is appropriate for the positioning of the sensor 600 relative to the operation of the track shifting mechanism, and the relative distance between the sensor's location on the vehicle and the vehicle's gripping device 404, such that the vehicle's gripping device 404 is positioned over the access opening 112 when the sensor 600 detects the end 506 of the track wall 502 at the intersection 504.

[0092] 9, the sensor arrangement of the present invention comprises one or more sensors 600 connected to the remotely operated vehicle 50. These sensors are mounted on the vehicle in a position such that the sensors 600 can directly detect when the gripping device 404 is properly positioned over the access opening 112, as described below.

[0093] 10A and 10B show an alternative embodiment of a sensor 600. The sensor 600 comprises a sensor body 602 on which are mounted a plurality of emitters 604 and detectors 606, specifically a leading emitter 604, a first trailing emitter 604', and a second trailing emitter 604''. The emitters 604 emit an energy beam 608 that is detected by the detector 606. The beam 608 traverses a recess 610. In the embodiment shown in FIG. 10A, the sensor body 602 is L-shaped, with the emitter 604 mounted on the short leg of the L and the detector mounted near the end of the long leg of the L, the space between them defining the recess 610. In the embodiment shown in FIG. 10B, the emitter and detector are mounted on extended legs 612, the space between them defining the recess 610.

[0094] FIG. 11 shows a sensor 600 mounted on the underside of the remotely operated vehicle 50. The sensor 600 is mounted to a body frame 614. The second set of wheels 14 (one of which is shown) can be raised and lowered as part of a track shifting operation. When the wheels 14 are lowered, the sensor 600 is raised. When the wheels 14 are raised, the sensor 600 is lowered. FIG. 12 again shows the sensor 600 mounted on the body frame 614, but shows a second sensor 600' mounted on a movable wheel frame 616. During a track shifting operation, the wheel frame 616 moves up and down with the wheels 14. In contrast to the sensor 600, the sensor 600' is lowered when the wheels 14 are lowered and is raised when the wheels 14 are raised. Thus, the sensor 600 is lowered onto the track when the vehicle travels in a first direction, and the sensor 600' is lowered onto the track when the vehicle travels in a second direction.

[0095] 13 shows a sensor 600 lowered into a groove 501 of a track 503. As can be seen, the track wall 502 blocks the beam 608 from reaching its corresponding detector.

[0096] 14 shows sensor 600 facing intersection 504. As discussed above, track 503 terminates at intersection 504 at terminus 506. Thus, as shown, beam 608 is not blocked by track wall 502 at the intersection.

[0097] This is also shown in Figures 15 and 16, which show an embodiment of the sensor from Figure 10A with a leading emitter 604 (with corresponding beams 608), a first trailing emitter 604' and a second trailing emitter 604''. For clarity, the vehicle 50 has been omitted. In Figure 15, for clarity, only a short leg of the L-shaped sensor body (on which the emitters are mounted) is shown. Figures 15 and 16 show the sensor 600 appropriately positioned with respect to the intersection 504. As shown, the sensor 600 is positioned with respect to the intersection 504 such that the leading beam 608 is blocked by the end 506 of the track wall 502, while the first trailing beam 608' and the second trailing beam 608'' are positioned within the intersection so that they can reach their corresponding detectors. As can be seen from Figure 16, the distance between each emitter corresponds to the allowable dimensional tolerance of the sensor position between the track walls in the track. According to one embodiment, the distance between the leading emitter (604, generating beam 608) and the first trailing emitter (604') is less than the width of the track wall (502), and the distance between the first trailing emitter (604', generating beam 608') and the second trailing emitter (604'', generating beam 608'') is 0-4 mm less than the width of the groove (501) of the track (503), preferably 2-4 mm less. Thus, the sensor can deviate less than 2 mm, preferably 1-2 mm, and most preferably 1.5 mm, in the groove.

[0098] 17 and 18 show the sensor as it progresses towards the proper position. As the vehicle approaches the intersection adjacent to the target access opening, the sensor first passes the end 506' of the first track wall 502'. As the sensor moves forward, it first detects the leading beam 608, then the first trailing beam 608'. The second trailing beam 608'' is still intercepted by the track wall 502. As the vehicle progresses further, the beam 608 is eventually intercepted by the second end 506'' of the second track wall 502'', and is positioned as shown in FIGS. 15 and 16. Until then, the sensor, through communication with the control system 500, knows that the vehicle is not yet in the proper position.

[0099] FIG. 19 shows the sensor advanced past the proper position. The sensor 600 has advanced so that the leading beam 608 and the second trailing beam 608'' are detected, while the first trailing beam 608' is blocked by the second track wall 502''. If necessary, to reposition the vehicle, the vehicle can be reversed until the leading beam 608 is blocked, as shown in FIG. 15.

[0100] Figure 20 (viewed in conjunction with Figure 9) shows that sensors 600 and 600' are mounted on vehicle 50 such that the sensors are positioned as shown in Figures 15 and 16 such that when the sensors detect an adjacent intersection 504, the vehicle's gripping device 404 is positioned over the target access opening 112. In Figure 20, the vehicle body has been omitted for clarity, but the location of wheels 14 and 12 is shown when viewed in conjunction with Figure 9.

[0101] In the preceding description, various aspects of a track sensor array for a storage and retrieval system have been described with reference to an exemplary embodiment. For purposes of explanation, specific numbers, systems and configurations have been set forth to provide a thorough understanding of the system and how it works. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the exemplary embodiment, as well as other embodiments of the system that are apparent to those skilled in the art to which the disclosed subject matter pertains, are deemed to be within the scope of the present invention.

[0102] List of Reference Numbers Prior art (Figs. 1 to 5): 1 Prior Art Automated Storage and Retrieval Systems 100 Framework Structure 102 Framework structure upright members 104 Storage Grid 105 Storage Column 106 Storage Container 106' Special location of storage container 107 Stack Section 108 Rail System 110 Parallel rail in the first direction (X) 111 Parallel rail in the second direction (Y) 112 Access opening 119 First Port Column 120 Second Port Column 201 Prior Art Container Transport Vehicles 201a Vehicle body of container transport vehicle 201 201b Drive means / wheel arrangement / first wheel set in first direction (X) 201c Drive means / wheel arrangement / second wheel set in second direction (Y) 301 Prior art cantilever container transport vehicle 301a Vehicle body of container transport vehicle 301 301b Drive means / first wheel set in first direction (X) 301c Drive means / second wheel set in second direction (Y) 304 Grasping Device 401 Prior Art Container Transport Vehicles 401a Vehicle body of container transport vehicle 401 401b Drive means / first wheel set in first direction (X) 401c Drive means / second wheel set in second direction (Y) 404 Grasping Device 404a Lift Band 404b Grip 404c Guide pin 404d lift frame 500 Control System 501 Groove 502 Upward protruding member / track wall 503 orbit 504 Intersection 506 End of track wall 508 510 X First Direction Y Second Direction Z third direction

[0103] Vehicle embodiment 10 Vehicle body 12 First set of wheels 12D 1st set of driving wheels 12P 1st Passive Wheel Set 13D Vehicle corners in relation to driving wheels 13P Vehicle corners related to passive wheels 14 Second set of wheels 14D 2nd set of driving wheels 14P 2nd Passive Wheel Set 15 Drive motor for second wheel set 16 Motor section 17 Part of the first orbital shift mechanism 18 Drive motor 19 Part of the first orbital shift mechanism 20 Cavity 22 Cavity 26 Battery 28 Exterior Wall 30 Crosspiece 32 Roof support 34 Protective Fence 50 Remotely Operated Vehicles COG center of gravity D1 Distance between the driving vehicle and the corner D2 Distance between the passive vehicle and the corner 600 / 600' Sensor 602 Sensor body 604 Emitter 606 Detector 608 Beam 610 Recess 612 Legs 614 Main frame 616 Wheel Frame

Claims

1. 1. An orbital sensor array comprising: An automated wheeled vehicle (50) arranged to travel along a grid-based rail system (108), said rail system comprising a plurality of parallel rails (110) arranged in a first direction (X) and a plurality of parallel rails arranged in a second direction (Y), said rails in said first and second directions intersect perpendicularly to form a plurality of intersections (504) defining a plurality of grid access openings (112), each rail providing a single track (503) or a pair of parallel tracks for wheels (14, 12) of said vehicle. an automated wheeled vehicle (50) provided with either: each track is in the form of a groove (501) defined by an upwardly projecting track wall (502), said track wall terminating at an end of said intersection (506); and said vehicle can change its direction of travel from said first direction to said second direction by alternately raising or lowering said set of wheels into and out of said tracks, said first set of wheels being arranged for travel in said first direction and said second set of wheels being arranged for travel in said second direction; b. a sensor (600) mounted on the vehicle, the sensor (600) being arranged such that the sensor is raised or lowered when the first wheel set is raised or lowered; Equipped with The sensor i. a sensor body (602) having a recess (610) arranged to receive a track wall of a track when said first wheel set is lowered into said track; ii. a plurality of emitters (604), each arranged to emit a beam of energy (608), and one or more corresponding detectors (606) arranged to detect the beam of energy from the emitters; Equipped with iii. the emitters and the corresponding detector(s) are arranged on opposite sides of the recess such that, when the first wheel set is lowered into the track, the track wall blocks the beams emitted from the emitters from reaching their corresponding detectors; iv. A track sensor array, wherein the sensors are mounted on the vehicle at locations that allow beams from emitters to reach their corresponding detectors when a predetermined portion of the vehicle is positioned over an access opening of interest.

2. 2. The track sensor arrangement of claim 1, wherein the predetermined portion of the vehicle is a gripping device (404) arranged to grip a storage container (106) stored in a storage column (105) below the access opening.

3. 2. The track sensor array of claim 1, wherein the sensor comprises a leading emitter (604), a first trailing emitter (604'), and a second trailing emitter (604''), and the sensor is mounted on the vehicle in a position such that the gripping device of the vehicle is aligned over an access opening of a target when the beam (608) of the leading emitter is blocked from reaching its corresponding detector (606) by an adjacent intersection structure, while the beams (608', 608'') of the first and second trailing emitters reach their corresponding detectors.

4. 4. The track sensor array of claim 3, wherein the distance between the leading emitter (604) and the first trailing emitter (604') is less than the width of the track wall (502), and the distance between the first trailing emitter (604') and the second trailing emitter (604'') is 0-4 mm less, preferably 2-4 mm less, than the width of the groove (501) of the track (503).

5. 2. The track sensor array of claim 1, wherein the distance between the two emitters corresponds to a predetermined tolerance of the position of the vehicle relative to the intersection.

6. The orbital sensor array of claim 1 further comprising a control system (500) in electronic communication with said sensors.

7. 2. The track sensor array of claim 1, wherein the sensor body is L-shaped, the emitters arranged on a short leg of the L, and the detectors arranged on a long leg of the L.

8. 1. A method for determining the position of a motor vehicle operating on a grid-based rail system (108), the rail system comprising a plurality of parallel rails (110) arranged in a first direction (Y), the rails in the first direction and the rails in a second direction intersecting perpendicularly to form a plurality of intersections (504) defining a plurality of grid access openings (112), each rail being provided with either a single track (503) or a pair of parallel tracks for wheels (14, 12) of the vehicle, each track being in the form of a groove (501) defined by upwardly projecting track walls (502), the track walls terminating at ends (506) of the intersections, the vehicle being able to change its direction of travel from the first direction to the second direction by alternately raising or lowering a set of wheels into and out of the tracks, a first set of wheels being arranged for travel in the first direction and a second set of wheels being arranged for travel in the second direction, the method comprising: a. providing a sensor (600), said sensor comprising: i. a sensor body (602) having a recess (610) arranged to receive a track wall of a track when said first wheel set is lowered into said track; ii. a plurality of emitters (604), each arranged to emit a beam of energy (608), and one or more corresponding detectors (606) arranged to detect the beam of energy from the emitters; Equipped with iii. the emitters and the corresponding detector(s) are arranged on opposite sides of the recess such that when the first wheel set is lowered into the track, the track wall blocks the beams emitted from the emitters from reaching their corresponding detectors; b) mounting said sensor on said vehicle in a position such that a beam from an emitter can reach its corresponding detector while a predetermined portion of said vehicle is positioned over an access opening of a target; c) lowering the first wheel set of the vehicle into a track as the vehicle travels in the first direction, the sensors also being lowered so that the track walls enter the recesses and block the beams from the emitters from reaching their corresponding detectors; d. driving the vehicle in the first direction until the beam from the emitter passes through the end of a track wall at an intersection adjacent an access opening of the target; e. stopping the vehicle when the sensor is positioned relative to the adjacent intersection such that the predetermined portion of the vehicle is aligned over the target access opening; A method comprising:

9. 9. The method of claim 8, wherein the predetermined portion of the vehicle is a gripping device (404) arranged to grip an item stored beneath the access opening.

10. 9. The method of claim 8, wherein the item is a container (106) from a stack of containers arranged in a storage column (105) below the access opening.

11. 9. The method of claim 8, wherein the sensor comprises a leading emitter (604), a first trailing emitter (604'), and a second trailing emitter (604''), the emitters being positioned on the sensor body (602) such that the beam (608) of the leading emitter is blocked from reaching its corresponding detector (606) by a track wall (502''), while the first and second emitters are positioned at an intersection (504) such that their beams (608', 608'') reach their corresponding detectors, and the gripping device of the vehicle is aligned over the access opening.

12. 12. The method of claim 11, wherein the structure that blocks the beam from the leading emitter when the gripping device is aligned over the access opening is a terminus (506) of a track wall.

13. 13. The method of claim 12, wherein the distance between the leading emitter (604) and the first trailing emitter (604') is smaller than the width of the track wall (502), and the distance between the first trailing emitter (604') and the second trailing emitter (604'') is 0-4 mm smaller, preferably 2-4 mm smaller, than the width of the groove (501) of the track (503).

14. a. The beam from the leading emitter (604) and the beam from the first subsequent emitter (604') are detected by their corresponding detectors, while the beam from the second subsequent emitter (604'') is blocked from reaching its detector; or b. The beams from the leading emitter (604) and the second trailing emitter (604'') are detected by their corresponding detectors, while the beam from the first trailing emitter (604') is blocked; or c. The beams from all three emitters are detected by their corresponding detectors.

12. The method of claim 11, further comprising determining that the vehicle is misaligned with respect to the target access opening if one of the following conditions is met:

15. 15. The method of claim 14, further comprising the step of repositioning a vehicle determined to be out of position by moving the vehicle until the beam from the leading emitter is blocked from reaching its detector while the beams from the first and second trailing emitters are being detected.

16. 9. The method of claim 8, wherein the sensors are in electronic communication with a control system (500), the control system directing the positioning of the vehicle in response to inputs from the sensors.

17. An automated storage and retrieval system, comprising: a grid-based rail system (108) comprising a plurality of parallel rails (110) arranged in a first direction (X) and a plurality of parallel rails arranged in a second direction (Y), the rails in the first and second directions intersecting perpendicularly to form a plurality of intersections (504) defining a plurality of grid access openings (112), each rail being provided with either a single track (503) or a pair of parallel tracks for the vehicle wheels (14, 12), each track being in the form of a groove (501) defined by upwardly projecting track walls (502), the track walls terminating at terminal ends (506) of the intersections; b. A track sensor array according to any one of claims 1 to 7; An automated storage and retrieval system.

Images