Tool for detecting the positioning of container handling vehicles in a storage system

Abstract

Tools, methods, computer program products, and systems for detecting positioning of a first container handling vehicle on a grid-based rail system of an automated storage and retrieval system, the rail system being part of a framework structure, the rail system comprising a first set of parallel rails arranged to guide movement of the container handling vehicle in a first direction (X) across the top of the framework structure and a second set of parallel rails arranged perpendicular to the first set of rails to guide movement of the container handling vehicle in a second direction (Y) perpendicular to the first direction (X), the first and second sets of parallel rails dividing the rail system into a plurality of grid cells, and the framework structure comprising upright members defining storage columns for storing containers within the framework structure.

Description

[Technical field]

[0001] (Technical field) The present invention relates to an automated storage and retrieval system for the storage and retrieval of containers, and more particularly to a system and method for locating a failed container handling vehicle on a grid and guiding a first failed container handling vehicle to a known location. [Background technology]

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

[0003] The framework structure 100 comprises upright members 102 and a storage volume comprising 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 on top of each other to form stacks 107. The members 102 may typically be 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 handling vehicles 201, 301, 401 can be operated to raise storage containers 106 from, lower storage containers 106 into, and transport storage containers 106 above the storage columns 105. The rail system 108 comprises a first set of parallel rails 110 arranged to guide movement of the container handling vehicles 201, 301, 401 in a first direction X across the top of the framework structure 100, and a second set of parallel rails 111 arranged perpendicular to the first set of rails 110 to guide movement of the container handling vehicles 201, 301, 401 in a second direction Y that is perpendicular to the first direction X. The containers 106 stored in the columns 105 are accessed by the container handling vehicles 201, 301, 401 via access openings 112 in the rail system 108. The container handling 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 upright members 102 of the framework structure 100 may be used to guide the storage containers during lifting and unloading of the containers from the columns 105 and during lowering of the containers into the columns. The stacks 107 of containers 106 are typically freestanding.

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

[0007] Each prior art container handling vehicle 201, 301, 401 also comprises a lifting device for vertical transport of the storage container 106, e.g. for raising 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, which can be lowered from the vehicle 201, 301, 401 such 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 handling vehicle 301, 401 is shown in Figures 3 and 4 with reference numbers 304, 404. The gripping device of the container handling device 201 is positioned in the vehicle body 201a of Figure 2.

[0008] Conventionally, and for the purposes of the present application, Z=1 identifies the top layer of storage containers, i.e., the layer immediately below the rail system 108, Z=2 identifies the second layer below the rail system 108, and Z=3 identifies the third layer. In the exemplary prior art disclosed in FIG. 1, Z=8 identifies the bottom layer of the storage containers. Similarly, X=1...n and Y=1...n identify the location of each storage column 105 in the horizontal plane. As a result, using the Cartesian coordinate system X, Y, Z shown in FIG. 1 as an example, the storage container identified as 106' in FIG. 1 can be said to occupy storage position X=17, Y=1, Z=6. The container handling vehicles 201, 301, 401 can be said to travel in layer 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 volume of the framework structure 100 is often referred to as a grid 104, and the possible storage locations within this grid are referred to as storage cells. Each storage column may be identified by 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 handling 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. The storage space may comprise an internally arranged cavity within the car body 201a, as shown in Figures 2 and 4 and described, for example, in WO 2015 / 193278 and WO 2019 / 206487, the contents of which are incorporated herein by reference.

[0011] Figure 3 shows an alternative configuration of a container handling vehicle 301 having a cantilever structure. 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 covering an area having dimensions in the X and Y directions approximately equal to the lateral extent of the storage column 105, for example, as described in 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 handling 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, for example as disclosed in International Patent Application Publication No. WO 2014 / 090684 or International Patent Application Publication No. WO 2019 / 206487.

[0014] The rail system 108 typically comprises rails having grooves in which the vehicle wheels run. Alternatively, the rails may comprise upwardly protruding elements and the vehicle wheels may comprise flanges to prevent derailment. These grooves and upwardly protruding elements are collectively known as tracks. Each rail may comprise one track, or each rail may comprise two parallel tracks.

[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 and parallel tracks in both the X and Y directions.

[0016] In the framework structure 100, the majority of the columns 105 are storage columns 105, i.e., columns 105 where the storage containers 106 are stored in stacks 107. However, some columns 105 may have other purposes. In FIG. 1, columns 119 and 120 are dedicated columns used by container handling vehicles 201, 301, 401 to drop off and / or pick up the storage containers 106, so that they can be transported to an access station (not shown) where the storage containers 106 can be accessed from outside the framework structure 100, or transferred from or into the framework structure 100. In the art, such a place is usually called a "port" and the column in which this port is located can be referred to as the "port column" 119, 120. The transport to the access station may be in any direction: 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 handling vehicle and transported to port columns 119, 120 for further transport to an access station. Note that the term "inclined" refers to the transportation of storage containers 106 with an overall transport orientation somewhere between horizontal and vertical.

[0017] In FIG. 1 , the first port column 119 may, for example, be a dedicated drop-off port column where container handling vehicles 201, 301 can drop off storage containers 106 to be transported to an access station or transfer station, and the second port column 120 may be a dedicated pick-up port column where container handling vehicles 201, 301, 401 can pick up storage containers 106 transported from an access station or transfer station.

[0018] An access station may typically be a picking or stock station where products are removed from or placed into a storage container 106. At a picking or stock station, the storage container 106 is typically not removed from the automated storage and retrieval system 1 but is returned into the framework structure 100 once accessed. A port may also be used to transfer a storage container to another storage facility (e.g., to another framework structure or to another automated storage and retrieval system), to a transportation vehicle (e.g., a train or truck), or to a manufacturing 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] When a storage container 106 stored in one of the columns 105 disclosed in FIG. 1 is accessed, one of the container handling vehicles 201, 301, 401 is commanded to retrieve the target storage container 106 from its location and transport it to the drop-off port column 119. This operation involves moving the container handling vehicle 201, 301 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 handling vehicle 201, 301, 401, and transporting the storage container 106 to the drop-off port column 119. When the target storage container 106 is located deep within the stack 107, i.e., when one or more other storage containers 106 are positioned above the target storage container 106, the operation also involves temporarily moving the storage container positioned above before lifting the target storage container 106 from the storage column 105. This step, referred to in the art as "digging", may be performed by the same container handling vehicle that is used to subsequently transport the target storage container to the drop-off port column 119, or by one or more other cooperating container handling vehicles. Alternatively, or in addition, the automated storage and retrieval system 1 may have container handling 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 alternatively be transferred 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 handling vehicles 201, 301, 401 is commanded to pick up the storage container 106 from the pickup port column 120 and transport it to a location above the storage column 105 where it is to be stored. After any storage container 106 positioned at or above the target location in the stack 107 is removed, the container handling vehicle 201, 301, 401 positions the storage container 106 in the desired location. The removed storage container 106 may then be lowered back into the storage column 105 or transferred to another storage column 105.

[0024] To monitor and control the automated storage and retrieval system 1, for example, to monitor and control 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 handling vehicles 201, 301, 401 so that the desired storage containers 106 can be delivered to the desired locations at the desired times without the container handling vehicles 201, 301, 401 colliding with each other, the automated storage and retrieval system 1 includes a control system 500, typically computerized, typically including a database for keeping track of the storage containers 106.

[0025] When a container handling vehicle breaks down on the grid, several problems can appear. One problem is to retrieve the broken down container handling vehicle, and another problem is to actually locate the broken down container handling vehicle. This is actually a problem that can escalate quickly if the robot cannot locate it quickly. The reason is that the container handling vehicle that has a breakdown may actually travel quite a distance before coming to a stop, and the central computer system does not know where the broken down container handling vehicle is, which means that other container handling vehicles are likely to collide with the broken down container handling vehicle.

[0026] Even if a broken-down container handling vehicle is located on the grid, it still needs to be transported to a known destination, such as a cell on the grid, or to a service center for repair. A common solution to this is that the entire grid can be stopped so that people can get on the grid and push the container handling vehicle back to the service area. This is costly and time consuming. [Prior art documents] [Patent documents]

[0027] [Patent Document 1] International Publication No. 2015 / 193278 [Patent Document 2] Norwegian Patent No. 317366 Summary of the Invention [Means for solving the problem]

[0028] (overview) The invention is set forth and characterized in the independent claims, while the dependent claims describe further features of the invention.

[0029] In one aspect, the invention relates to a tool for detecting positioning of a first container handling vehicle on a grid-based rail system of an automated storage and retrieval system, the rail system being part of a framework structure, the rail system comprising a first set of parallel rails arranged to guide movement of the container handling vehicle in a first direction (X) across the top of the framework structure and a second set of parallel rails arranged perpendicular to the first set of rails to guide movement of the container handling vehicle in a second direction (Y) perpendicular to the first direction (X), the first and second sets of parallel rails dividing the rail system into a plurality of grid cells, the framework structure comprising upright members defining storage columns for storing containers within the framework structure, the tool comprising an upper surface provided with a formation to allow pick-up of the tool by a lift device of a second container handling vehicle working on the rail system, and the tool including a sensor for detecting positioning of the first container handling vehicle on the rail system.

[0030] Sensors for determining the positioning of the first container handling vehicle may be located on the side or bottom of the tool, the sensors may be cameras, lidar, proximity sensors, or any other type of sensor capable of detecting objects surrounding it, and the tool may be fitted with two or more sensors.

[0031] The tool may have a tool support fixture on at least one side for pushing the first container handling vehicle to a known location.

[0032] The tool may have a wireless communication device, a power source, and a controller for performing measurements and communicating with a central computer system.

[0033] The tool may have a set of legs that allow the tool to be placed on a grid.

[0034] The tool support fixture may rest on rails around the grid cell when the tool is lowered into the grid cell.

[0035] The tool may have feet attached to it that rest in tracks around the grid cells when the tool is placed on the grid.

[0036] In a second aspect, the invention relates to a method for detecting positioning of a first container handling vehicle on a grid-based rail system of an automated storage and retrieval system, the rail system being part of a framework structure, the rail system comprising a first set of parallel rails arranged to guide movement of the container handling vehicle in a first direction (X) over the top of the framework structure and a second set of parallel rails arranged perpendicular to the first set of rails to guide movement of the container handling vehicle in a second direction (Y) perpendicular to the first direction (X), the first and second sets of parallel rails dividing the rail system into a plurality of grid cells, the framework structure comprising upright members defining storage columns for storing containers within the framework structure, the method comprising: picking up a tool using a lift device of a second container handling vehicle operating on the rail system; transporting the tool to a location at least one cell away from a last known location of the first container handling vehicle; determining the positioning of the first container handling vehicle using the tool; and instructing the second container handling vehicle carrying the tool to return and place the tool in its storage location.

[0037] Additionally, tools are used arranged on a grid to monitor conditions within the rail system, and multiple tools are arranged around the grid.

[0038] In a third aspect, the present invention relates to a system for detecting positioning of a first container handling vehicle on a grid-based rail system of an automated storage and retrieval system, the rail system being part of a framework structure, the rail system comprising a first set of parallel rails arranged to guide movement of the container handling vehicle in a first direction (X) over the top of the framework structure and a second set of parallel rails arranged perpendicular to the first set of rails to guide movement of the container handling vehicle in a second direction (Y) perpendicular to the first direction (X), the first and second sets of parallel rails dividing the rail system into a plurality of grid cells, the framework structure comprising upright members defining storage columns for storing containers within the framework structure, and the system comprising tools that may be carried by the container handling vehicle.

[0039] In a fourth aspect, the invention relates to a computer program product comprising instructions executed on a computer controlling a system to produce commands that are sent to command a second container handling vehicle to pick up the tool using a lift device of the second container handling vehicle operating on the rail system, to command the second container handling vehicle to transport the tool to a location at least one cell away from the last known location of the first failed container handling vehicle, to command the second container handling vehicle to determine the positioning of the first failed container handling vehicle using the tool, and to command the second container handling vehicle carrying the tool to place the tool back in its storage location.

[0040] By using this solution, it is possible to find where a failed container handling vehicle is located on the grid when the central computer system knows where the failed container handling vehicle is, and further, to steer the failed container handling vehicle to a known or serviceable location if it is unable to start and run properly on its own. [Brief description of the drawings]

[0041] The following drawings are included to facilitate an understanding of the invention and illustrate embodiments of the invention, which are given by way of example only.

[0042] [Figure 1] FIG. 1 is a perspective view of a framework structure of a prior art automated storage and retrieval system.

[0043] [Diagram 2] FIG. 2 is a perspective view of a prior art container handling vehicle having cavities arranged therein for carrying storage containers therein.

[0044] [Diagram 3] FIG. 3 is a perspective view of a prior art container handling vehicle having a cantilever for carrying storage containers underneath.

[0045] [Figure 4] FIG. 4 is a perspective view of a container handling vehicle with a central cavity solution.

[0046] [Diagram 5] FIG. 5 is a perspective view of one embodiment of the present invention displaying a tool for detecting the positioning of a failed first container handling vehicle on the grid-based rail system of an automated storage and retrieval system.

[0047] [Figure 6] FIG. 6 is a perspective view of the embodiment from FIG. 5 showing the equipment inside the tool.

[0048] [Figure 7] FIG. 7 is a perspective view of a tool according to the embodiment of FIG. 5, in which a broken-down first container handling vehicle is being transported by a container handling vehicle to a destination close to the area having the breakdown.

[0049] [Figure 8] FIG. 8 is a perspective view of the embodiment of the invention according to FIG. 5, in which the tools are arranged in a grid of an automated storage and retrieval system.

[0050] [Figure 9] FIG. 9 is a perspective view of the embodiment of the invention according to FIG. 5, in which the tools are arranged in a grid of an automated storage and retrieval system.

[0051] [Figure 10] FIG. 10 is a side view of another embodiment of the invention in which the tool is carried by a container handling vehicle.

[0052] [Figure 11] FIG. 11 is a perspective view of the invention according to the embodiment from FIG. 10, where the tool is carried by a container handling vehicle when performing measurements.

[0053] [Figure 12] FIG. 12 is a side view of a third alternative embodiment of the present invention in which the tool is carried by a container handling vehicle while taking measurements.

[0054] [Figure 13] FIG. 13 is a side view of the embodiment of the invention from FIG. 12 with tools positioned on a grid of an automated storage and retrieval system.

[0055] [Figure 14] FIG. 14 is a perspective view of a third embodiment of the present invention in which a tool is placed on a grid of an automated storage and retrieval system while the tool is performing measurements.

[0056] [Figure 15] FIG. 15 is a top view of a tool being used to assess the position of a disabled first container handling vehicle while being carried by another container handling vehicle.

[0057] [Figure 16] FIG. 16 is a front view of the tool used to push the disabled first container handling vehicle sideways to a known location.

[0058] [Figure 17] FIG. 17 is a side view of a tool used to estimate the position of a first container handling vehicle that has broken down in front of the tool.

[0059] [Figure 18] FIG. 18 is a side view of a tool being used to push the first disabled container handling vehicle to a known location.

[0060] [Figure 19] FIG. 19 is a side view of a container handling vehicle having a mounted sensor and lidar. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0061] (Detailed Description) In the following, embodiments of the invention will be discussed in more detail with reference to the accompanying drawings, in which it will be understood, however, that the drawings are not intended to limit the invention to the subject matter shown in the drawings.

[0062] The framework structure 100 of the automated storage and retrieval system 1 is constructed according to the prior art framework structure 100 described above in relation to Figures 1 to 3, i.e. a number of upright members 102 and a number of horizontal members 103 supported by the upright members 102, further comprising a first upper rail system 108 in the X and Y directions.

[0063] The framework structure 100 further comprises storage compartments in the form of storage columns 105 provided between the members 102, 103, wherein the storage containers 106 are stackable in stacks 107 within the storage columns 105.

[0064] The framework structure 100 can be of any dimension. In particular, it is understood that the framework structure can be significantly wider and / or longer and / or deeper than disclosed in Figure 1. For example, the framework structure 100 may have a horizontal extent of greater than 700 x 700 rows and a storage depth of greater than 12 containers.

[0065] 4 shows a top perspective view of a central cavity solution container handling vehicle with the lift platform lowered, which has guides 404 to help the lift platform properly interface with the containers in the storage columns.

[0066] Additionally, container handling vehicles are seen to have a larger footprint than columns. The additional space can be used to store batteries, electronics, and communications equipment, etc.

[0067] Although the present invention is designed to be carried by container handling vehicles having a cantilever solution, the tool can also be used to detect container handling vehicles having a central cavity solution.

[0068] The tool of the present invention is in the form of a container used in a storage and retrieval unit to store items. The container has a box shape with four sides and a bottom. Furthermore, like the storage containers used in the storage and retrieval system, the tool has an area to receive a gripper from the lift platform of a container handling vehicle so that it can be reliably lifted by the container handling vehicle.

[0069] The tool support fixture of the present invention can be in the form of a continuous edge around the top of the tool, or it can be an edge that follows the length of each side to the corner guide.

[0070] One embodiment of an automated storage and retrieval system in accordance with the present invention will now be discussed in more detail with reference to FIGS.

[0071] FIG. 5 is a perspective view of one embodiment of the present invention displaying a tool for detecting the positioning of a failed first container handling vehicle on the grid-based rail system of an automated storage and retrieval system.

[0072] This one embodiment of the invention displays a tool having the shape of a container. The tool is box-shaped with four sides and a bottom. In this image, there is no lid or top on the tool, but a lid or top could be used in this embodiment without changing the operation or use of the tool.

[0073] At least one bumper is attached to each side of the tool. These tool support fixtures are used as a barrier between the failed (first) container handling vehicle and the vehicle carrying the tool, helping to prevent the containers from hitting each other and causing damage to each other after the failed (first) container handling vehicle is positioned. Additionally, these tool support fixtures can be used as rests to ensure that the tool is kept at the correct level when placed on the grid in order to detect the failed (first) container handling vehicle.

[0074] It can further be seen that each of the sides of the tool extending outwardly from below the cantilever arm of the container handling vehicle has a sensor. The sensor can be a camera, but also any other sensor that can be used to locate and determine the distance to a stalled container handling vehicle. In one embodiment of the invention, there can be a camera in addition to at least one sensor on each side of the tool. The camera can be used to locate the stalled container handling vehicle and the sensor can be used to determine the distance, for example. In one configuration, a pair of distance sensors are positioned on either side of the camera. However, this can be changed without compromising the operability of the tool. The camera can be used as the only sensor to detect a failed container handling vehicle, or the camera can be used in addition to one or more sensors to detect the location of the failed container handling vehicle, for example by using image analysis to determine the location on the grid.

[0075] The tool is shaped such that it fits into the opening of the column on the grid. The tool is then lowered into the column until it rests on the tool support fixture. The bottom of the tool support fixture rests on rails that provide a frame of horizontal members around the opening of the column in which the tool is placed. The fuller extent of these horizontal members provides the grid of the storage and retrieval system.

[0076] A contact member is located on the top of the tool support fixture, this knob being the only place the tool interacts with a disabled container handling vehicle.

[0077] There can be one or more tool support fixtures on each side of the container handling vehicle. In the image presented in Figure 5, there are two tool support fixtures on each of the sides that are intended to make contact with the failed container handling vehicle.

[0078] In this image, you can see the presence of a radio antenna on at least one side of this embodiment of the invention, which allows the tool to receive and transmit commands to both the container handling vehicles that carry it and / or the central computer system that keeps track of the entire storage and retrieval system.

[0079] In an alternative solution, the antenna may be located within the tool.

[0080] Additionally, the wireless antenna allows the tool to communicate measurements from the sensors and / or cameras to the container handling vehicle and / or a central computer system.

[0081] In a further solution, the antenna makes it possible to communicate with a disabled container handling vehicle.

[0082] The antenna can also be used to communicate with other similar tools located on the grid. This allows the tools to use triangulation to determine the distance and location of the failed container handling vehicle. Triangulation signals can be sent together from the tool to be picked up by the failed container handling vehicle, which can be used to receive triangulation signals from the failed container handling vehicle.

[0083] FIG. 6 is a perspective view of the embodiment from FIG. 5 showing the equipment inside the tool. In this image, the tool is positioned inside the column opening. As can be seen, the tool fits into the column opening. A tool support fixture secured to the side of the tool ensures that the tool rests at the correct height within the grid cell opening. The tool support fixture extends from the side of the tool to the midpoint of the rail. At their maximum extent, the bumper and contact members extend the width of the rail.

[0084] Inside the tool is a controller box 601, which controls the operation of the tool and the communication between the tool and the container handling vehicles and the central computer system. The operation of the tool includes collecting data from sensors to locate the failed container handling vehicles. The tool can also perform analysis and evaluation of the collected data.

[0085] The controller box is powered by at least one power source. The power source can be a battery or a capacitor, or both. The power source can be stored inside the tool together with the controller box. Furthermore, the power source can be charged by a charger in a charging station where the tool is stored when the tool is not in use. Alternatively, the power source in the tool can be charged by the battery of the container handling vehicle, for example, via an electrical or inductive coupling of the lifting device of the container handling vehicle when it is supplied by power from the battery of the container handling vehicle. It is also possible to have both charging solutions on the tool, for example, contacts when the tool is placed in the charging station and contacts adjacent to the formation for connecting to the lifting device.

[0086] Additionally, plastic corner guides can be seen in the image. The plastic corner guides are constructed to make it easier to guide the tool into the column opening. Also, the corner guides have a rounded or flat shape that faces the corners of the column opening to reduce the risk of the tool getting stuck in the column opening.

[0087] From the controller you can also see the battery and the wiring for both the sensor and antenna.

[0088] In Figure 6 the tool only has tool support fixtures on three sides to ensure that the side closest to the body of the container handling vehicle does not have a tool support fixture that can become entangled with the inside of the container handling vehicle cantilever.

[0089] However, if the height of the tool support fixture is below a certain level, there can be a tool support fixture on all sides of the tool, as shown in FIG.

[0090] FIG. 7 is a perspective view of the tool according to the embodiment of FIG. 5, where the broken down container handling vehicle is being carried by the container handling vehicle to a destination close to the area having the fault. Here, a container handling vehicle with a cantilever solution is shown carrying the tool to a position on the grid. In this solution, data from the sensors is collected as the container handling vehicle carries the tool. Once the data is collected from the sensors, calculations and analysis of the data are performed and if the location of the broken down container handling vehicle is established, the container handling vehicle carrying the tool can use the tool to push the broken down container handling vehicle either to a location known to the central computer system or to a service area.

[0091] The solutions shown in Figures 5-8 may only use the sensors and / or cameras when the tool is carried by a container handling vehicle. Due to the tool support fixture being positioned above the height of the sensors and cameras, collection of data from the sensors and cameras is not possible due to the fact that they are below the surface of the grid. The tool may be configured to return to a sleep mode when it is placed on the grid and then switch to an active mode when it is picked up by a container handling vehicle.

[0092] However, if the tool support fixture is longer, the tool can be placed on the grid and data from the sensors can be collected. For example, the tool can be fitted with a tool support fixture that extends below the level of the sensors and cameras to facilitate collection of data from the sensors.

[0093] Figure 8 is a perspective view of an embodiment of the invention according to Figure 5, where the tool is located in the grid of an automated storage and retrieval system. This is an example where the tool is located on the grid in a sleep state. In this state, the tool is waiting for an order from the central computer system and a container handling vehicle to pick up the tool. Since the antenna is located above the surface of the grid, the tool may potentially transmit a signal to a failed container handling vehicle that can be used to triangulate the signal from the failed container handling vehicle to locate the failed container handling vehicle.

[0094] In one scenario, the tools can be placed on a grid and go into sleep mode until a central computer system tells them to wake up and search for a failed container handling vehicle.

[0095] The tool uses an antenna to find the general location of the failed container handling vehicle. After the general location of the failed container handling vehicle is established, a different container handling vehicle is sent to pick up the tool. That container handling vehicle carries the tool to the area where the originally collected data indicated the failed container handling vehicle. There, the tool uses its sensors and / or cameras to get a detailed location of where the failed container handling vehicle is. The container handling vehicle carrying the tool may then use the tool to push the failed container handling vehicle to a known location where it can start again or to a service area where it can be repaired if the failed container handling vehicle cannot start again.

[0096] Once the procedure is completed, the tool is placed back into sleep mode.

[0097] FIG. 9 is a perspective view of the embodiment of the invention according to FIG. 5, in which the tools are arranged in a grid of an automated storage and retrieval system.

[0098] Here we can see the first container handling vehicle malfunctioning on the grid. The cause of the malfunction appears to be a wheel derailment, which causes the container handling vehicle and the central computer system to lose track of the exact location of the malfunctioning container handling vehicle.

[0099] In one embodiment of the present invention, the tools may be stored on a grid as shown in this figure, or may be stored in a specially dedicated location. In this scenario, the central computer system sends an instruction to an available, for example, a second container handling vehicle, to pick up the tool from where it is stored. This second container handling vehicle picks up the tool and transports it to a location close to the last known location of the failed first container handling vehicle.

[0100] When the second container handling vehicle reaches its destination, the tool is instructed to perform measurements. Once the data from the measurements is collected, the data can be transmitted to a central computer system and processed to find the location of the failed first container handling vehicle. The data can also be transferred to the central computer system in real time and processed continuously.

[0101] Once the data is processed and the failed first container handling vehicle is located, the central computer system sends instructions to a second container handling vehicle to push the failed first container handling vehicle to either a known location on the grid or a service station.

[0102] After the first broken-down container handling vehicle has been transported to the correct location, the tool can then be transported to its appropriate location.

[0103] FIG. 10 is a side view of another embodiment of the invention in which the tool is carried by a container handling vehicle.

[0104] In this embodiment, a second container handling vehicle is carrying a slightly different embodiment of the invention where the tool has a longer tool support fixture that allows the sensors on the sides of the tool to be above the level of the grid when the tool is placed on the grid.

[0105] Additionally, additional sensors are mounted on the tool. In this embodiment, there is a lidar 1001 mounted on the bottom of the tool. This is mounted such that the light from the lidar spreads outward to the front and sides of the container handling vehicle.

[0106] FIG. 11 is a perspective view of the invention according to the embodiment from FIG. 10, where the tool is carried by a container handling vehicle when performing measurements.

[0107] Here, measurements made by the tool are taken while a container handling vehicle is carrying the tool, and light from the lidar is shown emanating from the tool in a fan shape.

[0108] If the first container handling vehicle that has failed is in the lidar's search area, it will be detected. The second container handling vehicle can use the tool support fixture on the tool to push the first container handling vehicle that has failed to reach a known location on the grid or to a service area.

[0109] FIG. 12 is a side view of a third alternative embodiment of the present invention in which the tool is carried by a container handling vehicle while taking measurements.

[0110] Here, a third embodiment of the invention is displayed. It can be seen that the tool has a set of feet attached to it. The feet allow the tool to be placed on top of a grid. By using the feet to place the tool on top of a grid, the feet allow for the use of a lidar attached to the underside of the tool.

[0111] The feet also allow other sensors to be elevated above the grid. This can make it easier to find the first container handling vehicle with a failed sensor. In particular, the camera can benefit from being elevated above the grid to give a better line of sight. Also, by using the feet to raise the tool, it is possible to obtain a large search area using only one lidar. If the lidars were placed on the sides of the tool, each lidar would have a smaller search area, requiring more lidars making the tool more expensive. However, this is also a possible solution to the invention.

[0112] Figure 13 is a side view of the embodiment of the invention from Figure 12, where the tool is positioned on the grid of an automated storage and retrieval system. Here, the tool is elevated above the surface of the grid using its feet and placed on the grid. Here, it is possible to see the lidar attached to the bottom of the tool. The lidar also has a free line of sight forward and to the side of the container handling vehicle.

[0113] 14 is a perspective view of a third embodiment of the invention in which a tool is placed on a grid of an automated storage and retrieval system while the tool is performing measurements. Light from the lidar is shown here emanating from the tool in a fan shape. If there is something in the path of the light from the lidar, it will bounce back to the lidar and it is possible to calculate the shape, position and distance to the obstacle from the light received by the lidar.

[0114] FIG. 15 is a top view of a tool being used to assess the position of a disabled first container handling vehicle while being carried by another container handling vehicle.

[0115] This is an image of a method for using the tool, where the tool is carried by a second container handling vehicle. The tool uses its sensors to estimate the distance and position of the failed first container handling vehicle.

[0116] Fig. 16 is a front view of a tool used to push a broken-down first container handling vehicle sideways to a known location. When the tool of Fig. 15 has located the broken-down first container handling vehicle, a second container handling vehicle uses the tool to push the broken-down first container handling vehicle using a contact member attached to the tool support fixture. As shown in this image, the second container handling vehicle can use the tool to push the broken-down first container handling vehicle from the side.

[0117] FIG. 17 is a side view of a tool used to estimate the position of a first container handling vehicle that has broken down in front of the tool.

[0118] Here it is shown that the tool can also be used to position a container handling vehicle positioned in front of it. This tool can be used to push out a disabled first container handling vehicle from behind, as shown in FIG. 18.

[0119] Additionally, in order to steer the failed first container handling vehicle, for example to a service station, if the failed first container handling vehicle will not start, the second container handling vehicle needs to be able to use tools to push the failed first container handling vehicle from all three sides.

[0120] FIG. 19 is a side view of a container handling vehicle having a mounted sensor and lidar.

[0121] In this embodiment, there is a lidar 1001 mounted on top of the second container handling vehicle. It is mounted such that light from the lidar spreads outward in all directions around the container handling vehicle.

[0122] The second container handling vehicle has at least one sensor on each vertical side. The sensor may be a camera, but also any other sensor that can be used to locate the stalled first container handling vehicle and determine the distance to it. In one embodiment of the invention, there may be at least one camera in addition to the at least one sensor on each side of the container handling vehicle. The camera may be used to locate the stalled container handling vehicle and the sensor may be used to determine the distance, for example. In one configuration, a pair of distance sensors is positioned on either side of the camera. However, this can be changed without compromising the maneuverability of the container handling vehicle. The camera may be used as the only sensor to detect a failed container handling vehicle, or the camera may be used in addition to one or more sensors to detect the location of the failed container handling vehicle, for example by using image analysis to determine the location on a grid.

[0123] In the preceding description, various aspects of the delivery vehicle and automated storage and retrieval system according to the present invention have been described with reference to exemplary embodiments. 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 illustrative embodiments, as well as other embodiments of the system that are apparent to those skilled in the art to which the disclosed subject matter pertains, are deemed to be within the scope of the present invention.

[0124] (List of reference numbers) Conventional technology (Figs. 1 to 4): 1 Prior Art Automated Storage and Retrieval Systems 100 Framework Structure 102 Upright members of framework structures 103 Horizontal members of framework structures 104 Storage Grid 105 Storage Column 106 Storage Container 106' Specific location of storage container 107 Stack 108 Rail System 110 Parallel rail in the first direction (X) 110a: first rail in first direction (X) 110b second rail in first direction (X) 111 Parallel rail in the second direction (Y) 111a First rail in second direction (Y) 111b second rail in second direction (Y) 112 Access opening 119 First Port Column 120 Second Port Column 201 Prior Art Container Handling Vehicles 201a Body of container handling vehicle 201 201b Drive means / wheel arrangement, first direction (X) 201c Drive means / wheel arrangement, second direction (Y) 301 Prior art cantilever container handling vehicles 301a Body of container handling vehicle 301 301b Driving means in the first direction (X) 301c second direction (Y) driving means 401 Prior Art Container Handling Vehicles 401a Body of container handling vehicle 401 401b Driving means in the first direction (X) 401c Driving means in the second direction (Y) 501 Tool Support Fixture 502 Contact member 503 Camera 504 Distance Sensor 505 Corner Guide 506 Container Side 507 Antenna 601 Controller Box 602 Battery 603 Sensor Cable Sensor measurement distance from 701 to 1001 Rider 1201 Foot X First Direction Y Second Direction Z third direction

Claims

1. A tool for detecting the position of a first container handling vehicle on a grid-based rail system of an automated storage and retrieval system, wherein the rail system is part of a framework structure, and the rail system comprises a first set of parallel rails arranged to guide the movement of a container handling vehicle in a first direction (X) across the top of the framework structure, and a second set of parallel rails arranged perpendicular to the first set of rails to guide the movement of the container handling vehicle in a second direction (Y) perpendicular to the first direction (X), wherein the first and second sets of parallel rails divide the rail system into a plurality of grid cells, and the framework structure comprises upright members defining storage columns for storing containers within the framework structure. The tool comprises a top surface having a formation that allows the tool to be picked up by a lift device of a second container handling vehicle operating on the rail system, and the tool includes a sensor for detecting the position of the first container handling vehicle on the rail system.

2. The tool according to claim 1, wherein the sensor for determining the position of the first container handling vehicle is located on the side or bottom surface of the tool.

3. The tool according to claim 1, wherein the sensor may be a camera, a lidar, a proximity sensor, or any other type of sensor capable of detecting an object surrounding it.

4. The tool according to claim 1, wherein two or more sensors may be attached to the tool.

5. The tool according to claim 1, wherein the tool has a tool support and fixing device on at least one side for pushing the first container handling vehicle to a known location.

6. The tool according to claim 1, comprising a wireless communication device, a power supply, and a controller for performing measurements and communicating with a central computer system.

7. The tool according to claim 1, wherein the tool has a set of legs that enable the tool to be positioned on the grid.

8. The tool support and fixing device is configured to rest on the rails around the grid cell when the tool is lowered into the grid cell, according to any one of claims 1 to 7.

9. The tool according to any one of claims 1 to 7, wherein the tool has feet attached to the tool that rest within the tracks around the grid cells when the tool is placed on the grid.

10. A method for detecting the position of a first container handling vehicle on a grid-based rail system of an automated storage and retrieval system, wherein the rail system is part of a framework structure, and the rail system comprises a first set of parallel rails arranged to guide the movement of a container handling vehicle in a first direction (X) across the top of the framework structure, and a second set of parallel rails arranged perpendicular to the first set of rails to guide the movement of the container handling vehicle in a second direction (Y) perpendicular to the first direction (X), wherein the first and second sets of parallel rails divide the rail system into a plurality of grid cells, and the framework structure comprises upright members defining storage columns for storing containers within the framework structure, and the method is: The tool is picked up using the lift device of a second container handling vehicle operating on the rail system, Transporting the tool to a location at least one cell away from the last known location of the first container handling vehicle, The position of the first container handling vehicle is determined using the tool, Instructing the second container handling vehicle that is transporting the tools to return the tools to their storage location and place them there. Methods that include...

11. The method according to claim 10, wherein the tool is positioned on the grid and used to monitor the conditions within the rail system.

12. The method according to claim 11, wherein multiple tools are arranged around the grid.

13. A system for detecting the position of a first container handling vehicle on a grid-based rail system of an automated storage and retrieval system, wherein the rail system is part of a framework structure, and the rail system comprises a first set of parallel rails arranged to guide the movement of a container handling vehicle in a first direction (X) across the top of the framework structure, and a second set of parallel rails arranged perpendicular to the first set of rails to guide the movement of the container handling vehicle in a second direction (Y) perpendicular to the first direction (X), wherein the first and second sets of parallel rails divide the rail system into a plurality of grid cells, and the framework structure comprises upright members defining storage columns for storing containers within the framework structure. The system comprises a tool according to any one of claims 1 to 7, which can be transported by a container handling vehicle.

14. A computer program product comprising instructions executed on a computer controlling the system described in claim 13, wherein the computer program product generates a command, and the command is Commanding the second container handling vehicle to pick up the tool using the lift device of the second container handling vehicle operating on the rail system, Commanding the second container handling vehicle to transport the tool to a location at least one cell away from the last known location of the first malfunctioning container handling vehicle, The second container handling vehicle is instructed to determine the position of the first malfunctioning container handling vehicle using the aforementioned tool, To instruct the second container handling vehicle carrying the tools to return the tools to their storage location and place them back in place. A computer program product sent to perform a specific task.

Images