Apparatus for removing a storage container from a storage and retrieval system

Abstract

A robotic load handling device (130) for lifting and moving one or more stackable containers in a storage and retrieval system, wherein the storage and retrieval system comprises a lattice structure comprising a plurality of lattice members including a first set of lattice members and a second set of lattice members, the second set of lattice members being substantially perpendicular to the first set of lattice members such that the plurality of lattice members are arranged in a lattice pattern for guiding the movement of the load handling device on the lattice structure, the load handling device comprising: a) a container lifting mechanism comprising a container gripping assembly configured to releasably grip a container and a lifting drive mechanism configured to raise and lower the container gripping assembly; b) a wheel assembly (135), (136) comprising a first set of wheels for engaging a first set of lattice members for guiding movement of the load handling device in a first direction and a second set of wheels for engaging a second set of lattice members for guiding movement of the load handling device in a second direction, wherein the second direction is transverse to the first direction; c) a wheel positioning mechanism configured to selectively lower or raise the first set of wheels or the second set of wheels to engage or disengage with the first set of lattice members or the second set of lattice members; d) a receptacle 138 for receiving a power source, the receptacle having an externally accessible open upper end for receiving the power source in a substantially vertical direction and a charge receiving element for electrically coupling to a charge supply element of the power source to supply power to the wheel positioning mechanism and the container lifting mechanism, and comprising a frame supporting the above, the frame comprising a plurality of modular sub-frames 132(a, b), 133(a, b), 134(a, b) arranged as a vertical stack, and the receptacle 138 extending vertically through at least one of the plurality of modular sub-frames, the robotic load handling device (130).

Description

Technical Field

[0001] The present invention relates to an apparatus for removing a storage container from a storage and retrieval system. In particular, but not limited to this, the present invention relates to a robotic load handling device (also known as a load handling device) for handling storage containers in a storage and retrieval system having a grid framework structure.

Background Art

[0002] A storage and retrieval system 1 having a three-dimensional storage grid framework structure in which storage containers / bins are stacked on top of each other is well known. PCT Publication No. WO2015 / 185628A (Ocado) describes a known storage and fulfillment or distribution system in which a stack of bins or containers is arranged within a grid framework structure. The bins or containers are accessed by a remotely operated load handling device positioned on a track at the top of the grid framework structure. This type of system is schematically shown in FIGS. 1 to 3 of the accompanying drawings.

[0003] As shown in FIGS. 1 and 2, stackable containers known as storage bins or containers 10 are stacked on top of each other to form a stack 12. The stack 12 is arranged within a three-dimensional grid framework structure 14 in a warehouse environment or a manufacturing environment. The grid framework structure is composed of a plurality of storage columns or grid columns. Each grid of the grid framework structure has at least one grid column for storing a stack of containers. FIG. 1 is a schematic perspective view of the grid framework structure 14, and FIG. 2 is a top view showing the stack 12 of bins 10 arranged within the framework structure 14. Each bin 10 typically holds a plurality of product items (not shown), and the product items within the bin 10 may be the same or of different product types depending on the application. The bin 10 may also be referred to as a storage bin or container or storage container or tote.

[0004] Specifically, the three-dimensional lattice framework structure 14 includes a plurality of vertical uprights or upright members or upright columns 16 that support the horizontal lattice members 18, 20. A first set of parallel horizontal lattice members 18 is arranged perpendicular to a second set of parallel horizontal lattice members 20 so as to form a lattice structure or lattice 15 that includes a plurality of lattice cells 17. The lattice cells have openings through which a load handling device can lift a container or storage bin. In the lattice structure, the first set of parallel horizontal lattice members 18 intersect at intersections with the second set of parallel horizontal lattice members. The lattice structure is supported by the upright members 16 at each intersection, i.e., at the points where the lattice members intersect, such that the upright members are interconnected at their upper ends by the intersecting lattice members. The lattice members 16, 18, 20 are typically made of metal and are typically welded or bolted, or a combination of both. The storage bin or container 10 is stacked between the upright members 16 of the lattice framework structure 14 such that the upright members 16 prevent horizontal movement of the stack 12 of bins 10 and guide vertical movement of the storage bin 10.

[0005] The top level of the lattice framework structure 14 includes rails 22 arranged in a lattice pattern spanning the top of the stack 12. Referring further to FIG. 3, the rails 22 support a plurality of load handling devices 30. A first set 22a of parallel rails 22 guides movement in a first direction (e.g., the X direction) across the top of the lattice framework structure 14 of the robotic load handling devices 30, and a second set 22b of parallel rails 22 arranged perpendicular to the first set 22a guides movement in a second direction (e.g., the Y direction) perpendicular to the first direction of the load handling devices 30. In this way, the rails 22 enable lateral movement of the robotic load handling devices 30 in two dimensions in the horizontal X-Y plane such that the load handling devices 30 can be moved to any position above the stack 12.

[0006] A known load handling device or robotic load handling device with a transporter 32, also known as a bot 30 and shown in FIGS. 4 and 5, is described in PCT Patent Publication No. WO2015 / 019055 (Ocado) incorporated herein by reference. However, each load handling device 30 targets only a single lattice space or lattice cell of the lattice framework structure 14. Here, the load handling device 30 comprises a first set of wheels 34 at the front of the transporter 32 for engaging a first set of rails or tracks for guiding the movement of the device in a first direction and a pair of wheels at the rear of the transport means 32, and a second set of wheels 36 on each side of the transport means 32 for engaging a second set of rails or tracks for guiding the movement of the device in a second direction. The load handling device 30 comprises a wheel assembly comprising a second set of wheels 36. Each of the sets of wheels is driven to enable movement of the transport means in the X and Y directions along the rails. One or both sets of wheels can be moved vertically to lift the respective set of wheels away from the corresponding rail, thereby enabling the transport means to move in a desired direction, e.g., the X or Y direction, on the lattice structure.

[0007] WO2017 / 153583 (Ocado Innovation Limited) teaches a load handling device comprising a wheel positioning mechanism or direction changing mechanism for enabling lateral movement of the device in one of two transverse directions by enabling either the first set of wheels or the second set of wheels to selectively engage with the first set of rails or tracks or the second set of rails or tracks (22a or 22b). The wheel positioning mechanism comprises a complex configuration of linkage mechanisms driven by linear actuators or motors for selectively lowering or raising the first set of wheels or the second set of wheels to engage or disengage with the first set of tracks or rails or the second set of tracks or rails.

[0008] The payload handling device 30 includes a lifting mechanism for lifting the storage container from above, or a container lifting mechanism, or a crane mechanism. The crane mechanism includes a winch tether or cable 38 wound around a spool or reel (not shown) and a grapple device or container gripper assembly 39 in the form of a lifting frame. In this patent specification, the terms "grabber device" and "container gripping assembly" are used interchangeably as meaning the same mechanism. The lifting device includes a set of lifting tethers 38 for releasably connecting to the storage container 10, which extends vertically and is connected near or at the four corners of a lifting frame 39, separately known as a grabber device (one tether near each of the four corners of the grabber device). The grapple device 39 is configured to releasably grip the top of the storage container 10 in order to lift the storage container 10 from a stack of containers in a storage system of the type shown in FIGS. 1 and 2.

[0009] Wheels 34, 36 are arranged around the periphery of a cavity or recess in the lower part, known as the container receiving recess 41. The recess is sized to accommodate the container 10 when it is lifted by the crane mechanism, as shown in FIGS. 5(a, b). When within the recess, the container is lifted away from the underlying rails so that the transport means can move laterally to another location. When the target location, such as another stack, an access point within a storage system, or a conveyor belt, is reached, the bin or container can be lowered from the container receiving portion and released from the grapple device. The container receiving space may comprise a cavity or recess disposed within the transporter, as described, for example, in WO2015 / 019055 (Ocado Innovation Limited). Alternatively, the transporter of the load handling device may comprise a cantilever, as taught in WO2019 / 238702 (Autostore Technology AS), in which case the container receiving space is positioned below the cantilever of the load handling device. In this case, the grapple device is lifted by the cantilever such that the grapple device can engage the container, lift it from the stack, and place it into the container receiving space below the cantilever.

[0010] Power for the drive unit to operate the lifting mechanism and the wheel positioning mechanism is supplied from a rechargeable power source. The load handling device further comprises one or more auxiliary electrical components, such as a control device, one or more wire looms for carrying information from the control device and / or power from the rechargeable power source to the drive unit of the load handling device. For example, one or more load handling devices that are remotely operable on a grid structure are configured to receive commands from a master control device to retrieve a storage container from a specific storage location within the grid frame structure. Wireless communication and networks can be used to provide a communication infrastructure from the master control device to one or more load handling devices operating on the grid structure via one or more base stations. The control device within the load handling device is configured to control various drive mechanisms for controlling the movement of the load handling device in response to receiving the commands. For example, the load handling device can be commanded to retrieve a container from a storage column at a specific location on the grid structure. This command can include various movements in the X-Y directions on the grid structure. Upon reaching the storage column, the lifting mechanism is then actuated to grip and lift the storage container and place it into a container receiving space within the body of the load handling device, and in this case subsequently this storage container is transported to another location on the grid structure, generally known as a drop-off port. The container is lowered to an appropriate picking station so that items can be removed from the storage container. Movement of the load handling device on the grid structure also includes being commanded to move to a charging station, which is typically located at the periphery of the grid structure. The load handling device remains stationary at the charging station while the battery is being recharged. The charging period is a major cause of downtime for the load handling device and can be on the order of several hours. The rechargeable power source and the auxiliary electrical components of the load handling device are typically housed within the body of the load handling device.

[0011] Considering the numerous components required for a load handling device to operate on a lattice framework structure, including various motors, pulleys, rechargeable power sources, and auxiliary electrical components such as control panels, the assembly of individual components is one of the greatest costs in the manufacture of load handling devices. Since hundreds of load handling devices operating on a lattice framework structure are required, there is an increasing movement to optimize the mass production of load handling devices in order to achieve maximum economies of scale in a given production line. One of the factors in maximizing economies of scale in the mass production of load handling devices is the number of operations required to assemble the load handling device, and in this case, efficiency improvements can be obtained by assembling the load handling device with a minimum number of operations. This will require using fewer components and / or components that can be easily assembled into one. By enabling the components of the load handling device to be easily assembled into one, the load handling device is conducive to automation because there are fewer complex operations required to assemble the various components of the load handling device into one.

[0012] Therefore, there is a need for load handling devices that are easy to assemble, lightweight, and have lower manufacturing costs.

Summary of the Invention

[0013] The present invention alleviates the above problems by providing a robotic load handling device (also known as a load handling device) having a frame structure comprising a plurality of modular sub-frames arranged as a vertical stack, each of the plurality of modular sub-frames being connectable to another modular sub-frame within the vertical stack and providing corresponding functional features of the load handling device. These include, but are not limited to, wheel assemblies, wheel positioning mechanisms, container lifting mechanisms, and electrical components. The individual modular sub-frames are connectable, enabling modular sub-frames that provide various functions of the load handling device to be stacked vertically. To reduce the number of operations in the assembly or manufacture of the load handling device, it is desirable to reduce the number of modular sub-frames when assembling the modular sub-frames into one. This has the advantage of increasing the stability of the load handling device, because a plurality of components of the load handling device, some of which are positioned higher in the upper part of the load handling device, can be supported further below the frame, thereby lowering the center of gravity of the load handling device. This is particularly important for a load handling device having an installation area that occupies only a single lattice cell, where the lower part of the robotic load handling device has a container receiving space, as taught in WO2015 / 019055 (Ocado Innovation Limited). This also provides a more compact load handling device that makes maximum use of the space within the frame structure. However, reducing the number of modular sub-frames poses new problems in the manufacture of the load handling device. These include, but are not limited to, the structural integrity of the frame and the ability of the frame to accommodate all of the functional features of the load handling device. Reducing the number of modular sub-frames also limits the number of attachment points for supporting electrical components such as control devices and / or wiring looms from rechargeable power sources.The applicant has alleviated this problem by providing a receptacle supported by a frame that doubles as a battery chute for housing a power source and an attachment portion or attachment column for one or more of the components of a robotic load handling device. The present invention is thus a robotic load handling device for lifting and moving one or more stackable containers in a storage and retrieval system, the storage and retrieval system comprising a lattice structure comprising a first set of lattice members extending in a first direction and a second set of lattice members extending in a second direction, the second direction being substantially perpendicular to the first direction such that the plurality of lattice members are arranged in a lattice pattern for guiding the movement of the load handling device on the lattice structure, the load handling device comprising: a) a container lifting mechanism comprising a container gripping assembly configured to releasably grip the container and a drive mechanism configured to raise and lower the container gripping assembly; b) a first set of wheels for engaging a first set of lattice members for guiding movement of the load handling device in the first direction and a second set of wheels for engaging a second set of lattice members for guiding movement of the load handling device in the second direction, wherein the second direction is substantially perpendicular to the first direction; c) a wheel positioning mechanism configured to selectively lower or raise the first set of wheels or the second set of wheels to engage or disengage with the first set of lattice members or the second set of lattice members; d) a receptacle for housing a power source, the receptacle having an externally accessible open upper end for receiving the power source in a substantially vertical direction, and a charging receptacle element for electrically coupling to a charge supply element of the power source to supply power to the wheel positioning mechanism and the container lifting mechanism, comprising a frame for supporting the same. The frame comprises a plurality of modular sub - frames arranged as a vertical stack, and the receptacle extends vertically through at least one of the plurality of modular sub - frames, providing a robotic payload handling device.

[0014] The components fundamental to the movement of the robotic payload handling device, such as the wheel assembly, wheel positioning mechanism, and container lifting mechanism, are highly restricted to a specific area of the robotic payload handling device. For example, it is essential that the wheel assembly is attached to the lower part of the frame for the robotic payload handling device to move on a grid structure, and the container lifting mechanism is positioned in the upper part of the robotic payload handling device such that a container gripping assembly or grapple device can be lowered and raised through the container receiving space. However, among the components of the robotic payload handling device, there are those that, while fundamental to the operation of the robotic payload handling device, are not essential to a specific location of the robotic payload handling device for its operation. These include, but are not limited to, electrical components such as a control device for controlling the container lifting mechanism and a power source. Optionally, the frame further supports electrical components including a control device for controlling the container lifting mechanism and the wheel positioning mechanism. The term "support" includes being supported directly by the frame and / or indirectly by the frame, i.e., via another component.

[0015] In the present invention, a robotic load handling device is provided with an area for attaching components, where the functional characteristics of the components are not determined solely by their location in the robotic load handling device. Since the location of the power source in the load handling device is not fundamental to the operation of the load handling device on the grid structure, the present invention provides a receptacle for accommodating and holding the power source within a separate area of the frame. The receptacle has an externally accessible open upper end for receiving the power source and a charge receiving element for electrically coupling to the charge supply element of the power source when the power source is lowered into the receptacle through the open upper end. Although the operation of the load handling device is not determined by the location of the power source, the stability of the load handling device depends on the location of the power source because the power source occupies a significant proportion of the weight of the load handling device. To enhance the stability of the robotic load handling device on the grid structure, in particular when the installation area of the robotic load handling device occupies the space within a single grid cell, it is essential that the center of gravity of the robotic load handling device is as low as possible within the body of the robotic load handling device. To improve the stability of the robotic load handling device while providing an attachment area for the electrical components of the robotic load handling device, the receptacle is partially deeply embedded within the frame of the robotic load handling device such that the receptacle extends vertically through at least one of a plurality of modular sub-frames. For the purpose of definition, the term "extends vertically through" also encompasses extending vertically through a horizontal plane in which at least one of a plurality of modular sub-frames is present.

[0016] Since the receptacle is partially embedded together with the frame of the load handling device, the receptacle can also form the core or battery chute of the load handling device. As a result, the receptacle can enable the construction of the load handling device, because the outer surface of the receptacle can help position one or more of the modular sub-frames relative to the receptacle, i.e., the receptacle can help ensure that one or more of the modular sub-frames are properly assembled in the construction of the load handling device.

[0017] Preferably, each modular sub-frame of the plurality of modular sub-frames comprises at least four connection blocks, and each of the at least four connection blocks is connected to two other connection blocks within a single modular sub-frame by one or more horizontal connection elements so as to form a rectangular frame structure, and at least four connection blocks of adjacent modular sections in the vertical direction can be connected as a vertical stack by one or more substantially vertical connection elements so as to form a frame comprising a plurality of rectangles.

[0018] Preferably, the frame is an open frame structure. The open frame structure is a three-dimensional open frame structure that defines a volume for housing at least a part of the lifting mechanism and / or the wheel assembly and / or the wheel positioning mechanism. For the purposes of the present invention, the term "open frame structure" means that an internal operating component of the load handling device, for example, any one of the spools for supporting the lifting tether of the container lifting mechanism, and / or the power supply, and / or the control unit, is visible from the outside of the load handling device so that the internal components providing the functional features of the load handling device are visible, that is, it is defined as a structure without external cladding. The adjacent rectangular frames in the vertical direction of the open frame structure define the volume region of the load handling device. For example, the open frame structure is a three-dimensional open frame structure.

[0019] In this case, the open frame structure comprises a plurality of modular sub-frames, and the plurality of modular sub-frames support a lifting mechanism, a wheel assembly, a wheel positioning mechanism, and electrical components. Each modular sub-frame of the plurality of modular sub-frames comprises at least four connection blocks, and each of the at least four connection blocks is connected to two other connection blocks within a single modular sub-frame by one or more horizontal connection elements so as to form a rectangular frame structure. The connection between a connection block in a single modular sub-frame and two other corner connection blocks can be direct to two adjacent connection blocks or indirect via another connection block. Not only are each of the at least four connection blocks connected by one or more horizontal connection elements to two other connection blocks within a single modular sub-frame so as to form a rectangular frame structure, but the at least four connection blocks enable the various modular sub-frames to be easily connectable as a vertical stack. The plurality of rectangular frames can in this case be connected to each other as a vertical stack by one or more vertical connection elements so as to form the open frame structure.

[0020] Various functions of the load handling device, such as a container lifting mechanism, a wheel assembly, a wheel positioning mechanism, and / or electrical components, are supported by the frame. The term "support" is construed to include being supported directly by the frame and / or indirectly by the frame via another component. For example, one or more of the electrical components can be supported by the frame via being attached to a receptacle.

[0021] To facilitate the assembly of the frame, optionally, one or more horizontal and / or vertical continuation elements comprise connecting rods or tubes. The connecting rods can be easily grasped and assembled to the blocks in various rotational directions. Thus, using connection blocks and connecting rods makes the assembly of the load handling device easier. Optionally, to assist in reducing the weight of the load handling device, the connecting rods comprise carbon fibers embedded in a polymer matrix. Preferably, one or more of at least four connection blocks of one or more of the plurality of modular sections are connected to one or more horizontal and / or vertical continuation elements by joints. The connection between the horizontal connecting element and the connection block by the joint optionally comprises an adhesive channel. To enhance the functionality of one or more of the four connection blocks, the adhesive channel is integrated into one or more of the at least four connection blocks. Preferably, one or more of the at least four connection blocks comprise one or more injection points in fluid communication with the adhesive channel for injecting adhesive into the continuous adhesive channel. Optionally, one or more of the connection blocks comprise sockets for receiving the ends of the connecting rods or tubes. Preferably, the sockets are integrally formed within the connection blocks. To secure the connecting rod or tube to the connection block, preferably, the socket has a substantially cylindrical inner wall configured to form an adhesive channel when the receiving end of the connecting rod is inserted into the socket. Preferably, one or more of the at least four connection blocks comprise one or more injection points in fluid communication with the socket for injecting adhesive into the adhesive channel. This helps to make it easy to connect one or more blocks of one or more of the plurality of modular sections with horizontal and / or vertical continuation elements.

[0022] Optionally, to enhance the structural integrity of the frame, at least one of the plurality of modular sub - frames is cross - braced by one or more cross - bracing members. Preferably, the one or more cross - bracing elements comprise intersecting cross - bracing elements. In addition to the horizontal and vertical connecting elements that provide structural support to the frame, one or more cross - bracing elements may extend across at least one modular sub - frame. The one or more cross - bracing elements can also provide additional support for tethering one or more components of the lifting mechanism and / or the wheel assembly and / or the wheel positioning mechanism and / or the electrical components. Optionally, the receptacle is supported by at least one intersecting brace of the plurality of modular sub - frames. The intersecting brace can provide an attachment portion for the receptacle. The intersecting brace can represent a boundary between the upper portion of the robotic handling device comprising the receptacle and the lower portion of the robotic load handling device comprising the wheel assembly and the container receiving space.

[0023] To reduce the problem of downtime due to charging, the load handling device can be powered by a replaceable power source. When the power source in the load handling device runs out, the depleted power source can be replaced with a fully - charged power source, and thus the downtime due to charging is reduced to the time to replace the power source rather than the time to charge the power source. By providing a receptacle that allows the power source to be inserted and removed vertically, the load handling device provides at least the following advantages compared to robotic load handling devices in the art, especially those where the power source is replaced horizontally: · The receptacle is externally accessible, and thus the power source can be conveniently and efficiently replaced without the need to open the body of the load handling device. This also allows the power source to be replaced while the load handling device remains on the track structure.

[0024] ·The robotic payload handling device is not required to present a particular side for power replacement, which provides flexibility regarding how the payload handling device is oriented on the track structure and the location of the peripheral equipment for power replacement.

[0025] ·The robotic payload handling device is not required to move horizontally to replace the power source, which frees up space on the track structure and eliminates the need for the payload handling device to have an auxiliary power source to supply power to the drive assembly after the power source is removed.

[0026] ·The robotic payload handling device is not required to provide a horizontal reaction force (e.g., using a braking mechanism) to prevent the payload handling device from moving during power insertion or removal, because the reaction force is in the vertical direction and is provided by the track structure under the payload handling device.

[0027] The power source may be a battery. The battery may be a rechargeable battery.

[0028] The receptacle may be externally accessible from above the load handling device. The receptacle may comprise an upward-facing opening, and the receptacle may be configured to removably receive power in a downward direction through the upward-facing opening. By doing so, the insertion of the power source into the receptacle and the charge receiving element between the power source and the receptacle is naturally assisted by the weight and gravity of the power source. The receptacle may be configured to couple to the power source when the power source is received vertically into the receptacle and to decouple from the power source when the power source is removed vertically from the receptacle. The receptacle may comprise a charge receiving element that is configured to electrically couple to the corresponding charge supply element of the power source when the power source is received vertically into the receptacle and to decouple from the charge supply element of the power source when the power source is removed vertically from the receptacle. The charge receiving element of the receptacle may comprise a male connector, and the charge supply element of the power source may comprise a female connector, or vice versa. As an alternative, the charge supply element and the charge receiving element may comprise electrical contact pads.

[0029] Optionally, to facilitate removal of the power supply from the receptacle, the receptacle extends vertically above the height of the frame, i.e., the receptacle protrudes above the frame. Having a receptacle that extends vertically above the frame allows the power supply to be more exposed compared to the rest of the robotic payload handling device. Further, this also allows the frame to be easily disassembled because it enables at least one of the modular sub-frames surrounding the receptacle to be easily removed from the payload handling device that will be serviced or replaced without the need to disassemble the other modular sub-frames. For example, the modular sub-frame surrounding the receptacle can be easily lifted around the receptacle. Optionally, the receptacle is removably attached to at least one of the plurality of modular sub-frames. The ability to removably attach the receptacle to at least one of the plurality of modular sub-frames provides greater access to the interior of the payload handling device for servicing or replacing one or more of the components of the payload handling device when the receptacle is removed from the frame. This is particularly in the area of one or more modular sub-frames occupied by the receptacle.

[0030] Since the power supply represents a significant proportion of the weight of the robotic payload handling device and since the receptacle is located on the upper part of the robotic payload handling device, it is important that the receptacle is firmly attached to the frame of the robotic payload handling device. The reason for this is 2m / s 2This is because the acceleration of the robotic payload handling device on a lattice structure that can achieve a certain size may cause the power supply to react within the receptacle, thereby applying an undesirable reaction force to the receptacle. Considering the weight of the power supply that can reach a size of 10 kg, the reaction of the power supply within the receptacle may cause fatigue to the attachment part between the receptacle and the frame, more specifically, to one or more of the modular sub-frames that provide support. In extreme cases, this may loosen the attachment between the receptacle and the frame. Optionally, the receptacle is integrated with at least one of the plurality of modular sub-frames to provide greater support to the receptacle so that it does not become detached within the frame. Optionally, the receptacle is connected to at least one of the plurality of modular sub-frames by at least one support pillar.

[0031] Preferably, the receptacle provides one or more attachment points for attaching one or more electrical components. The electrical components include, but are not limited to, a control unit for controlling the wheel assembly, the container lifting mechanism, and the wheel positioning mechanism, and / or a communication module comprising a transmitter and a receiver for respectively transmitting and receiving data to and from a base station via one or more antennas attached to the receptacle. For example, the receiver may be configured to receive via the antenna a wireless signal comprising data associated with an instruction from an external control unit related to the positioning or trajectory of the robotic payload handling device on the grid structure. A control device within the payload handling device is configured to control various drive mechanisms for controlling the movement of the payload handling device in response to receiving the instruction. For example, the payload handling device may be instructed to retrieve a container from a storage column at a particular location on the grid structure. This instruction may include various movements in the X-Y direction on the grid structure. Upon reaching the storage column, the lifting mechanism is then actuated to grip and lift the storage container and place it into a container receiving space in the body of the payload handling device, whereupon the storage container is then transported to another location on the grid structure, generally known as a drop-off port. The storage container is unloaded at an appropriate picking station so that items can be removed from the storage container. The movement of the payload handling device on the grid structure also includes the payload handling device being instructed to move to a charging station, which is typically located at the periphery of the grid structure. The position of the robotic payload handling device on the grid structure used to generate the trajectory of the robotic payload handling device on the grid structure is provided by wireless communication of signals generated from one or more sensors on the robotic payload handling device to an external control unit via a transmitter attached to the receptacle.Other electrical components that can be attached to the receptacle include a J-Switch, which is a receiver that does not rely on receiving instructions associated with the trajectory of the robotic payload handling device on the grid structure. This provides the robotic payload handling device with safety instructions to stop the movement of the robotic payload handling device on the grid structure when activated from the outside. This is to prevent the robotic payload handling device operating on the grid structure from injuring personnel on the grid structure.

[0032] Wiring the cables from the electrical components safely to the associated operating components of the robotic payload handling device, such as the container lifting mechanism, the lifting drive mechanism for operating the wheel assembly, and the wheel positioning mechanism, the robotic payload handling device further comprises a cable tray attached to the receptacle for wiring one or more electrical cables from the electrical components (such as a control device) attached to the receptacle to the container lifting mechanism and the wheel positioning mechanism. The cable tray provides a guide surface for routing the electrical cables to their corresponding components and provides guards that minimize the snagging of the electrical cables on any of the components. To prevent movement of the electrical cables on the cable tray, the cable tray further comprises one or more cable retaining clips for holding one or more cables to the cable tray. Optionally, the one or more cable retaining clips comprise a plurality of mooring elements configured to engage with the cable tray.

[0033] To accommodate the receptacle within the frame such that the receptacle extends vertically through at least one of the plurality of modular sub-frames without affecting the functional characteristics provided by at least one of the plurality of modular sub-frames, optionally, the container lifting mechanism i) a first set of spools and a second set of spools, each of the first set of spools and the second set of spools supporting a lifting tether having a first end moored to the container gripping assembly and a second end moored to its corresponding spool, ii) a first lifting shaft and a second lifting shaft, the first set of spools being mounted to rotate on the first lifting shaft, the second set of spools being mounted to rotate on the second lifting shaft, the first lifting shaft and the second lifting shaft being connected to a lifting drive mechanism to transmit rotation from an output of the lifting drive mechanism for raising and lowering the container gripping assembly, comprising The first lifting shaft and the second lifting shaft are spaced apart such that a receptacle is disposed between the first lifting shaft and the second lifting shaft.

[0034] Mounting a plurality of spools supporting the lifting tether to rotate on separate first and second lifting shafts allows the receptacle to extend between the first and second lifting shafts of the container lifting mechanism such that the receptacle can be partially "buried" within the frame. As a result, the power supply can be placed further below the frame, improving the stability of the robotic payload handling device. The receptacle being partially "buried" within the frame by being positioned between the first and second lifting shafts allows easy access to the plurality of spools simply by removing the receptacle from the frame, particularly when it is necessary to unwind the lifting tether on the spools.

[0035] To enable the receptacle to be partially "buried" within the frame, preferably, the first lifting shaft and the second lifting shaft are rotatably attached to at least one of a plurality of modular sub-frames surrounding the receptacle. For example, the first lifting shaft and the second lifting shaft can be rotatably attached to a connection block of the modular sub-frame. In other words, attaching the first set of spools and the second set of spools to the first shaft and the second shaft creates a space for accommodating at least a portion of the receptacle. Optionally, the lifting drive mechanism comprises a drive pulley and a plurality of timing pulleys connected by an endless belt so as to rotate together with the first set of spools and the second set of spools. Preferably, the drive pulley is driven by a single motor. The single motor, the plurality of timing pulleys, and the timing belt are configured to transmit rotation from the output of the single motor to raise and lower the container gripping assembly.

[0036] To simplify the structure of the receptacle and to minimize the weight of the frame, the receptacle comprises a plurality of connection blocks connected by a plurality of connection elements so as to define an open frame structure. Optionally, the receptacle comprises at least eight connection blocks, each of the eight connection blocks being connected to two other connection blocks in the horizontal plane by one or more horizontal connection elements and to one other connection block in the vertical plane by one or more vertical connection elements so as to form a cuboid frame structure. Alternatively, the receptacle may be made of metal and preferably may be formed from a folded metal sheet comprising a bottom wall (base) and upwardly rising side walls and end walls. Optionally, the receptacle comprises a metal box having an open upper end for receiving power substantially in the vertical direction. Preferably, the metal comprises aluminum. The advantage of using metal in the manufacture of the receptacle is to prevent or reduce any electromagnetic signal emitted from the battery and / or battery management electronics from interfering with the signal from the control device of the payload handling device, i.e., to function as a Faraday cage and shield. Making the receptacle from a metal sheet provides a continuous guide surface for receiving a power source, e.g., a battery, when it is lowered into the receptacle, as compared to making the receptacle from a plurality of connection blocks connected by a plurality of connection elements. This helps to properly position the power source within the receptacle and to properly guide the power source onto the electrical connector. Preferably, the receptacle comprises a base for supporting the power source and upwardly rising side walls and end walls extending from the base.

[0037] To cause the installation area of the load handling device to substantially occupy only the installation area of a single lattice space or cell, preferably, the frame defines a volume for accommodating a container receiving space. The container receiving space is a space for accommodating a container within the frame of the load handling device so that the load handling device can move on a track or lattice structure. The three-dimensional frame defines a volume having an upper portion and a lower portion, the upper portion accommodating a receptacle of the load handling device, and the lower portion accommodating the container receiving space.

[0038] One of the advantages of the load handling device being constructed by a plurality of connection blocks connected together and stacked vertically to form a plurality of rectangular frames is that the connection blocks provide not only structural components but also functional components to the load handling device. In other words, each of at least four connection blocks of each of the plurality of modular sub-frames is a separate connection block that provides both structural and functional components of the load handling device. This eliminates the need for separate structural components that provide the structural features of the load handling device and separate functional components attached to the structural components for the operation of the load handling device on the lattice structure, because one or more of the connection blocks can combine both the structural and functional aspects of the load handling device. Incorporating both structural and functional components of the load handling device into one or more of the connection blocks of the frame also reduces the number of parts when constructing the load handling device of the present invention, thus reducing the weight of the load handling device.

[0039] Preferably, one or more of the plurality of modular sub-frames comprise at least a part of a container lifting mechanism and / or a wheel assembly and / or a wheel positioning mechanism. For example, one or more of at least four connection blocks of one or more of the plurality of modular sub-frames comprise one or more attachment parts for pulleys. Optionally, one or more of at least four connection blocks of one or more of the plurality of modular sub-frames comprise one or more attachment parts for motors.

[0040] Optionally, at least a part of the container lifting mechanism and / or the wheel assembly and / or the wheel positioning mechanism is integrated into one or more of the plurality of modular sub-frames. For example, the attachment parts for attaching each of the wheels of the wheel assembly may be formed integrally with one or more of at least four connection blocks.

[0041] Optionally, any one of the lifting mechanism and / or the wheel assembly and / or the wheel positioning mechanism and / or the electrical components may be shared between two or more of the plurality of modular sections. For example, the wheel positioning mechanism comprises a cam mechanism comprising a cam having a cam profile with peaks and valleys, a cam follower, and a traveler for moving the cam follower along the cam profile so as to convert the movement of the cam along the cam profile into a vertical movement. The cooperation between the cam, the cam follower, and the traveler may be shared between two or more of the plurality of modular sections.

[0042] The present invention is A method of constructing a robotic load handling device comprising a frame, the frame a) a container lifting mechanism comprising a container gripping assembly configured to releasably grip a container and a lifting drive mechanism configured to raise and lower the container gripping assembly, and b) A first set of wheels for engaging a first set of lattice members for guiding movement of the load handling device in a first direction, and a second set of wheels for engaging a second set of lattice members for guiding movement of the load handling device in a second direction, wherein the second direction is substantially perpendicular to the first direction, c) A wheel positioning mechanism configured to selectively lower or raise the first set of wheels or the second set of wheels to engage or disengage with the first set of lattice members or the second set of lattice members, d) A charge receiving element for electrically coupling to a charge supply element of a rechargeable power source to supply power to the wheel positioning mechanism and the container lifting mechanism, supporting, the following steps, namely i) forming a plurality of modular sub-frames, each of the plurality of modular sub-frames being formed by connecting at least four connection blocks together by one or more horizontal connection elements, ii) connecting the connection blocks of adjacent modular sub-frames in the vertical direction by one or more vertical connection elements to connect the plurality of modular sub-frames as a vertical stack to form a frame, iii) attaching a receptacle for accommodating a power source to the frame such that the receptacle extends vertically through at least one of the plurality of modular sub-frames, the receptacle comprising a charge receiving element for electrically coupling to a charge supply element of the power source and an externally accessible open upper end for receiving the power source substantially vertically, providing a method.

[0043] Attaching the receptacle to the frame includes attaching the receptacle to at least one of a plurality of modular sub - frames. Optionally, the method further comprises the step of adhering the receptacle to at least one of a plurality of modular sub - frames. To further secure the receptacle to the frame, the method further comprises the step of bracing the receptacle to the frame by one or more cross - members or struts.

[0044] Preferably, each of the modular sub - frames is formed by inserting one or more of a plurality of horizontal connecting elements into openings in one or more of at least four connecting blocks. Preferably, the plurality of modular sub - frames are connected together as a vertical stack by inserting one or more vertical connecting elements into openings in one or more of at least four connecting blocks of adjacent modular sub - frames in the vertical direction. To improve the manufacturability of the load - handling device, preferably, the method further comprises the step of integrally forming at least a part of the container lifting mechanism and / or the wheel assembly and / or the wheel positioning mechanism from one or more of at least four connecting blocks of one or more of the plurality of modular sub - frames. By integrally forming at least a part of the functional components of the load - handling device from an open frame structure, more particularly from one or more of the connecting blocks of the open frame structure, the number of components required to construct a load - handling device having the desired functional characteristics of a load - handling device operable on a lattice frame structure is reduced. Optionally, one or more of the connecting blocks of at least four connecting blocks of one or more of the plurality of rectangular frames are formed by 3D printing or additive manufacturing to capture the various complex shapes of at least a part of the container lifting mechanism, the wheel assembly, and the wheel positioning mechanism.

[0045] The present invention further provides a method for replacing a power source within a receptacle of the robotic payload handling device as defined above. The method comprises the following steps, namely (i) vertically removing a first power source from the receptacle; and (ii) vertically inserting a second power source into the receptacle.

[0046] The payload handling device may remain stationary, at least in the horizontal direction (e.g., on the same grid cell of a track structure), from the time the first power source is removed until the second power source is inserted.

[0047] To prevent the power source from reacting when the payload handling device accelerates on a track of the grid structure, the frame is configured to lower the power source into the frame, such that the power source is received within the frame. To house the power source within the frame and thereby provide support to the power source as a result of forces generated when the robotic payload handling device accelerates on the track and the power source attempts to react, the present invention further provides a robotic payload handling device for lifting and moving one or more stackable containers in a storage and retrieval system, wherein the storage and retrieval system comprises a grid structure comprising a plurality of grid members including a first set of grid members and a second set of grid members, the second set of grid members being arranged in a grid pattern for guiding the movement of the payload handling device on the grid structure and being substantially perpendicular to the first set of grid members, and the payload handling device a) a container lifting mechanism comprising a container gripping assembly configured to releasably grip a container and a lifting drive mechanism configured to raise and lower the container gripping assembly; and b) A first set of wheels for engaging with a first set of lattice members for guiding the movement of the load handling device in a first direction, and a second set of wheels for engaging with a second set of lattice members for guiding the movement of the load handling device in a second direction, where the second direction is substantially transverse to the first direction, c) A wheel positioning mechanism configured to selectively lower or raise the first set of wheels or the second set of wheels to engage or disengage with the first set of lattice members or the second set of lattice members, d) A power compartment having an externally accessible open upper end for receiving power substantially vertically and a base for supporting the power, the power compartment comprising a charge receiving element for electrically coupling to a charge supply element of the power to supply power to the wheel positioning mechanism and the container lifting mechanism, a frame comprising the same, The frame comprises a plurality of modular sub-frames arranged as a vertical stack, the lifting drive mechanism is attached to at least one of the plurality of modular sub-frames, and the externally accessible open upper end of the power compartment is formed within at least one of the plurality of modular sub-frames to which the lifting drive mechanism is attached, providing a robotic load handling device.

[0048] Having an open upper end outside the power supply compartment formed within at least one of the plurality of modular sub-frames enables the power supply to descend into the frame of the robotic payload handling device. In this case, instead of the receptacle extending above the height of the frame, by "burying" the receptacle forming the power supply compartment within the frame, optionally, the receptacle can extend below the height of the frame or at least be flush with the height of the frame. To accommodate the externally accessible open upper end of the power supply compartment, the externally accessible open upper end of the power supply compartment is formed within at least one of the plurality of modular sub-frames to which the lifting drive mechanism is attached. To form the open upper end of the power supply compartment within at least one of the plurality of modular sub-frames to which the lifting drive mechanism is attached, the container lifting mechanism i) supports a first set of spools and a second set of spools, each of the first set of spools and the second set of spools supporting a lifting tether having a first end moored to the container gripping assembly and a second end moored to the corresponding spool, ii) a first lifting shaft and a second lifting shaft, the first set of spools being rotatably mounted on the first lifting shaft, the second set of spools being rotatably mounted on the second lifting shaft, the first lifting shaft and the second lifting shaft being connected to the lifting drive mechanism to transmit rotation from the output of the lifting drive mechanism for raising and lowering the container gripping assembly, The first lifting shaft and the second lifting shaft are spaced apart such that the externally accessible open upper end of the power supply compartment is disposed between the first lifting shaft and the second lifting shaft.

[0049] Preferably, each modular sub-frame of the plurality of modular sub-frames includes at least four connection blocks, and each of the at least four connection blocks is connected to two other connection blocks within one modular sub-frame by one or more horizontal connection elements to form a rectangular frame. At least four connection blocks of adjacent modular sections in the vertical direction are connectable as a vertical stack by one or more substantially vertical connection elements to form a frame including a plurality of rectangular frames. Preferably, the first lifting shaft and the second lifting shaft are rotatably attached to at least four modular connection blocks of at least one of the plurality of modular sub-frames to which the lifting drive mechanism is attached. Preferably, the externally accessible open upper end of the power supply section is formed from four corner pieces attached to at least one of the plurality of modular sub-frames to which the lifting drive mechanism is attached.

[0050] To support this when power is dropped into the frame of the robotic payload handling device, preferably the base is attached to at least one of a plurality of modular sub-frames positioned below at least one of the plurality of modular sub-frames to which the lifting drive mechanism is attached. In this case, the power section is distributed between two of the plurality of modular sub-frames, namely, the top modular sub-frame that forms the open upper end of the power section and the modular sub-frame below the top modular sub-frame that supports the base of the power section. Optionally, the base comprises a charge receiving element for electrically coupling to a charge providing element of the power supply when power is dropped into the power section. The charge receiving element electrically couples to the charge supply element of the power supply when the power supply is placed on the base. Preferably, the base is attached to at least one of the plurality of modular sub-frames via cross braces. Optionally, the frame defines a volume having an upper portion and a lower portion, the upper portion comprising a power section and the lower portion comprising a container receiving space.

[0051] The present invention further provides an automated storage and retrieval system comprising a lattice structure comprising a plurality of lattice members including a first set of lattice members and a second set of lattice members, the second set of lattice members being substantially perpendicular to the first set of lattice members such that the plurality of lattice members are arranged in a lattice pattern for guiding the movement of one or more payload handling devices operating on the lattice structure. at least one robotic payload handling device according to the present invention.

[0052] Further features and aspects of the present invention will become apparent from the following detailed description of exemplary embodiments made with reference to the drawings.

Brief Description of the Drawings

[0053]

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DETAILED DESCRIPTION OF THE INVENTION

[0054] The present invention has been devised in view of the known features of storage systems such as the lattice framework structure and the load handling device described above with reference to FIGS. 1 to 5. FIG. 7a is a schematic view of an example of a load handling device 130 according to the present invention. A typical load handling device in the art comprises a separate rigid framework or chassis, and the functional components of the load handling device, such as a lifting mechanism, a wheel positioning mechanism, a wheel assembly, a wheel drive assembly, and electrical components, such as a rechargeable power source and / or a control unit, are literally fixed to or attached to the framework. The fixing includes various fixing means such as bolts, screws, and / or welding. The framework is usually in the form of a tower having a height representative of the height of the load handling device. To ensure that the structural integrity of the rigid framework withstands the weight of the various functional components of the load handling device, the rigid framework is generally constructed from a metal such as aluminum or stainless steel. Cladding is fixed to the outside of the framework to form a transporter housing the functional mechanisms of the load handling device. The cumulative weight of the rigid framework and the various functional components of the load handling device results in the load handling device having a weight exceeding 150 kg. Compared with the load handling devices in the art, the load handling device according to the embodiment of the present invention shown in FIG. 7a has no cladding and mostly comprises an open frame structure 131. A plurality of modular sub-frames can be connected together as a vertical stack so as to form the open frame structure. Details of the assembly of the open frame structure of the load handling device will be considered further below.

[0055] According to an embodiment of the present invention, the structure of the load handling device 130 according to the present invention is based on the principle of having a modular system comprising a plurality of modules or modular sub-frames that can be connected as a vertical stack to provide various functional features of the load handling device. An example of the load handling device 130 incorporating the inventive concept of the present invention is shown in FIG. 7a, and various modular sections 132(a and b) to 134(a and b) providing various functional features of the load handling device are shown in FIGS. 8(a and b), and schematic views of various modular sub-frames constituting the load handling device are shown in FIGS. 9(a and b). FIG. 9a is a schematic view showing a simplified version of the frame 131 that supports the main operating components of the load handling device, which is the result of assembling the modular sub-frames 132a, 133a, 134a shown in FIG. 8a. FIG. 9b is a drawing showing a more simplified view of the components 140 of the load handling device shown in FIG. 9a, which is the result of assembling the modular sub-frames 132b, 133b, 134b shown in FIG. 8b. In a further aspect of the present invention, this modular system is integrated into the frame or framework 131 such that the frame is assembled from a plurality of modular sub-frames that can be connected to each other as a vertical stack to provide various functional features of the load handling device. Each of the modular sections 132(a and b) to 134(a and b) is provided by a modular sub-frame that can be connected together to form the frame 131 of the present invention. In a particular embodiment of the present invention, the frame 131 is configured as an open frame structure. However, the present invention is not limited to the frame being an open frame structure, and the frame may optionally comprise an external cladding attached to the outside of the frame. For the purposes of the description of the present invention, the frame in the particular embodiment shown in FIG. 7a will be described as an open frame structure.

[0056] In yet another aspect of the present invention, at least some of the functional components of the load handling device are integrally formed within the open frame structure of the load handling device. As can be appreciated from the exploded view of one face of the load handling device shown in FIG. 16, the various modular sub-frames 132c, 134c, 136c of the load handling device shown in FIG. 16 are provided with connection points 142 at the corners of the modules 132c, 133c, 134c to enable the various modular sub-frames 132c, 133c, 134c to be stacked vertically. Thus, each connection block for assembling the modular sub-frames into one can be envisioned as a corner bracket. In certain embodiments of the present invention shown in FIGS. 8(a and b) and FIG. 16, three modular sections 132(a, b, c), 133(a, b, c) and 134(a, b, c) are shown as being connectable as a vertical stack to form a modular system based on a hierarchy. Starting from the bottom modular section 132(a, b, c) and increasing the height of the load handling device, the three modular sections are labeled, for the purposes of the description of the present invention, as the first modular section 132(a, b, c), the second modular section 133(a, b, c), and the third modular section 134(a, b, c), each provided by the corresponding modular sub-frame. The three modular sections provide various functional features of the load handling device. In certain embodiments of the present invention, the various functional features of the load handling device can be shared among one or more of the modular sections 132(a, b, c), 133(a, b, c), and 134(a, b, c) of the load handling device 130. For example, the wheel positioning mechanism and the wheel drive assembly can be shared among two or more modular sections of the load handling device. The number of modular sections is not limited to three modular sections, and the various functional features of the load handling device can be divided among any number of modular sections.

[0057] The various functional features of the load handling device include, but are not limited to, a wheel assembly for enabling movement of the load handling device on a grid structure or track, a wheel drive assembly for driving the wheel assembly to enable the load handling device to move on the grid structure, a wheel positioning mechanism otherwise known as a direction changing mechanism, a container lifting mechanism for picking up and dropping off storage containers between the grid cells of the grid framework structure, and electrical or electronic components of the load handling device. As already discussed in the introduction to the patent specification, the electrical components may optionally comprise a control unit or control device 144a for controlling the operation of the wheel drive assembly, the wheel positioning mechanism, and the lifting drive mechanism of the container lifting mechanism. Usually, the drive mechanisms of the wheel drive assembly, the wheel positioning mechanism, and the container lifting mechanism comprise one or more electric motors. Other electrical components of the load handling device include, but are not limited to, a communication module for receiving instructions from an external central control system. The communication module 144b comprises a receiver for receiving instructions from an external control unit via a base station and a transmitter for transmitting a signal comprising data associated with the positioning and / or status of the load handling device on the grid structure via an antenna 145. The control device 144a communicating with the communication module 144b controls the movement of the load handling device on the grid structure in response to receiving instructions from an external central control system. The electrical components may also comprise a J-Switch 144c, which is a receiver separate from the communication module 144b and is configured to receive a safety signal from an external J-Switch transmitter in the event of an intrusion into the area occupied by the grid structure. In order to prevent one or more load handling devices operating on the grid structure from accidentally colliding with and injuring people on the grid structure, it is extremely important that the operation of the load handling device on the grid structure is disabled before entering the grid structure. Usually, a separate signal is sent to the load handling device to override the instructions from the external control unit, in addition to the signal sent to the communication module.When activated, J-Switch 144c removes power from the drive mechanism that powers the wheel assembly and / or the container lifting mechanism so that the payload handling device is forced to stop on the grid structure.

[0058] The open frame structure 131 of the robotic payload handling device is configured to support a power source (not shown) for supplying power to one or more of the components of the payload handling device, such as a wheel assembly for driving the payload handling device on the grid, a wheel positioning mechanism for changing direction on the grid, a container lifting mechanism for operating the container gripper assembly, and the electrical components discussed above. Typically, the power source is a rechargeable power source or battery. Examples of rechargeable batteries are lithium ion batteries, nickel cadmium batteries, nickel metal hydride batteries, lithium ion polymer batteries, thin film batteries, and smart battery carbon form based lead batteries. Many components of the payload handling device are supported by the open frame structure 131. If a number of components that are integrally formed with one or more of the modular sub-frames are not properly arranged, there is a risk that the packing of the components will be inefficient, resulting in large pockets of unused free space within the open frame structure, causing the open frame structure to become unduly large or bulky. Therefore, it is necessary to optimize the arrangement of the components of the payload handling device so as to optimize the use of the available space in the open frame structure while still providing the various functional features of the payload handling device. This in turn leads to optimizing the shape and / or size of the open frame structure of the payload handling device. In the present invention, this is partially solved by integrating some of the functional features of the components of the payload handling device into one or more of the modular sub-frames, as will be further discussed below. Such optimization of the available space is beneficial in reducing the size of the payload handling device, but there still remain pockets of open free space within the open frame structure that are not fully optimized.

[0059] For the power supply and electrical components of a robotic payload handling device, particularly the control device, communication module, and compared with the J-Switch, the degree of freedom in the design of other components of the payload handling device is very limited and does not affect the proper operation of the payload handling device on the grid structure. For example, in order for the payload handling device to move on the grid structure, the wheel assembly is positioned at the base or lower part of the frame 131, holds the storage container, and in order to lift this storage container from the stack within the grid frame structure into the container receptacle of the payload handling device, it is extremely important that the container gripper assembly is positioned above the container receiving space. Therefore, in order to provide a compact payload handling device, a balance must be struck between these components of the payload handling device, which have little freedom in the design of the open frame structure, and optimizing the shape and / or size of the open frame structure.

[0060] One or more of the electrical components and the power source have a high degree of design freedom in that they are not restricted to any particular location in the robotic payload handling device in order for the payload handling device to function on the grid structure. However, since the power source occupies a significant proportion of the total weight of the robotic payload handling device, the position of the power source affects the stability of the payload handling device on the grid structure. The lower the power source is positioned within the frame 131 of the payload handling device, the more stable the payload handling device becomes. To improve the stability of the payload handling device, in an embodiment of the present invention as shown in FIG. 7a, the payload handling device 130 further comprises a receptacle 138 that functions as a battery chute for accommodating the power source 138b within the open frame structure 131 (see FIGS. 7b, 8, and 9). In other words, the receptacle 138 is "embedded" within the open frame structure 131 such that the receptacle 138 extends vertically through at least one of the modular sub-frames 132, 133, 134 of the open frame structure 131. For the purposes of definition, the term "extends vertically through" also encompasses extending vertically through a horizontal plane in which at least one of the plurality of modular sub-frames is present. The receptacle 138 provides an individual area within the open frame structure for the power source 138b to be lowered into the open frame structure without colliding with other components of the payload handling device (see FIG. 7b). In other words, the receptacle 138 provides a safe power source compartment or "well" that is externally accessible above the payload handling device for lowering the power source into the open frame structure of the payload handling device within the open frame structure. The receptacle is depicted as having a rectangular parallelepiped shape, but may have other shapes such as a cylindrical shape, depending largely on the shape of the power source or its casing. The upper end of the receptacle is open and is externally accessible from above the payload handling device to allow the power source to be lowered into the receptacle.The receptacle 138 includes one or more electrical connectors or charge receiving elements configured to be electrically coupled to the charge supply element of a power supply. The charge receiving elements are configured to connect to the charge supply element of the power supply when the power supply is received vertically into the receptacle and to disconnect when the power supply is removed vertically from the receptacle.

[0061] In addition to providing an opening for the power supply to be lowered into the open frame structure of the load handling device, the receptacle also provides one or more location-independent attachment points within the load handling device for components of the load handling device. For example, in addition to housing the power supply, the receptacle may also provide one or more location-independent attachment points for attaching one or more of the electrical components (see FIG. 12). In this particular example, the control device 144a, the communication module 144b, and the J-Switch 144c are shown attached to the receptacle 138 in FIGS. 7 and 12. The presence of a receptacle that doubles up as a receptacle for housing the power supply and providing one or more attachment points for attaching one or more of the components of the load handling device and extending vertically through at least one of the modular sub-frames enables a more compact and easily assembled load handling device.

[0062] To facilitate the description of the present invention, particularly the architecture of the open frame structure, the various functional features of the load handling device 130 shown in FIG. 7 will be described first. However, the present invention is not limited to the examples of the various functional features of the load handling device described below, and in the present invention, other examples that can provide the same functional features of the load handling device are applicable. The description of the functional features of the load handling device is intended to provide examples of the functional features of the load handling device.

[0063] Wheel assembly As shown in FIG. 7, the wheel assembly includes a pair of wheels at the front portion 135 and a pair of wheels at the rear portion of the load handling device 130. For simplicity of explanation, the wheel assembly includes a pair of wheels 135 at the front portion of the load handling device and a pair of wheels at the rear portion of the load handling device, and is collectively referred to as the first set 135 of wheels. The first set 135 of wheels is oriented such that the load handling device can move in a first direction, i.e., the X direction of the Cartesian coordinate system. Similar to the first direction, for the load handling device to be able to move in both the X and Y directions on the grid structure, the wheel assembly includes a pair of wheels 136 on both sides of the load handling device for movement in a second direction that is substantially perpendicular to the first direction, i.e., the Y direction of the Cartesian coordinate system. For simplicity of explanation, these wheels are referred to as the second set 136 of wheels. In this case, for movement in the first direction on the grid structure, the first set 135 of wheels engages with the grid structure and the second set 136 of wheels disengages from the grid structure. Similarly, for movement in the second direction, the first set 135 of wheels disengages from the grid structure and the second set 136 of wheels engages with the grid structure. The wheels are rotatably attached to an open frame structure 131 via one or more wheel attachments 139, 141 (see FIGS. 8 and 15) and are configured to engage with the grid structure to enable the load handling device to move in both the X and Y directions along the grid structure.

[0064] To enable the load handling device to move in the first and second directions on the grid structure, the load handling device further includes a wheel drive assembly configured to drive each of the wheels of the wheel assembly.

[0065] Wheel drive assembly In certain examples of the present invention, each of the first set of wheels and the second set of wheels is driven by one or more motors (not shown) via a drive belt assembly 140 as described in PCT Application No. PCT / EP2021 / 055372 in the name of Ocado Innovation Limited, the details of which are incorporated herein by reference. In the particular embodiment shown in FIG. 7, a drive belt assembly 143a is provided for each set of wheels, and the drive belt assembly 143a comprises a drive belt pulley gear arrangement 143b for engaging the edges of a pair of wheels 135, 136 on one side of the load handling device. The rims of the pair of wheels comprise a plurality of gear teeth 147 for cooperating with the drive belt 146. A toothed drive belt engages both wheels. The drive belt 146 is guided by a slave wheel 148 attached to the open frame structure 131 of the load handling device 130 and a tensioning wheel arrangement 150. The tensioning wheel arrangement 150 is movably attached to the open frame structure 131 using a spring (not shown) and is intended to keep the drive belt 146 taut and maintain the engagement of the drive belt 146 with the wheels. A drive wheel 151 is provided attached to the open frame structure 131 (see FIG. 16). The drive wheel 151 is driven by a pulley and gear arrangement 143a connected to the shaft or drive shaft of the motor (not shown in FIG. 7). The rotation of the drive wheel 151 by the motor drives the pair of wheels by connection to the drive belt 146. The wheel drive assembly is provided for each pair of wheels of the first set 135 and the second set 136 of wheels. Thus, each of the pairs of wheels of the first set 135 of wheels is synchronously driven by their corresponding drive assemblies to move the load handling device in the X direction on the grid structure. Similarly, each of the pairs of wheels of the second set 136 of wheels is synchronously driven by their corresponding drive assemblies to move the load handling device in the Y direction on the grid structure.

[0066] The drive wheels 151 on both opposite sides of the load handling device 131 may share a common motor shaft such that each pair of drive wheels 151 is driven simultaneously at the same speed. As a result, only a single motor is required to drive the load handling device 130 in the forward and reverse directions in the first x direction, and only a single motor is required to drive the load handling device 130 in the forward and reverse directions in the second y direction. This configuration can advantageously reduce costs in terms of the space and the number of parts required in the load handling device. The first set 135 of wheels and the second set 136 of wheels can be selectively driven under the control of the load handling device.

[0067] A particular example of the wheel drive assembly of FIG. 7 includes a drive belt assembly 14a driven by a motor, but in the present invention, other configurations for driving the first set of wheels and the second set of wheels are applicable. For example, it will be appreciated that it may be possible to drive the load handling device using four motors in each of the first and second directions. For example, all of the wheels in the first set of wheels and the second set of wheels can be driven by individual hub motors each comprising an outer rotor configured to rotate about an inner hub. Specifically, the outer rotor comprises an outer surface arranged to engage a lattice structure (e.g., a track), and an inner surface comprising a ring-shaped permanent magnet arranged to rotate around a wheel hub or an inner hub comprising a stator of the hub motor. Typically, the stator comprises the coils of the hub motor. To drive each wheel of the first set 135 or the second set 136 of wheels, and as a result move the load handling device 130 in the first or second direction on the lattice structure, the outer rotor of the hub motor is configured to rotate about a rotation axis corresponding to the central axis of the corresponding wheel. The outer surface of the rotor may optionally comprise a tire for engaging a track or a rail.

[0068] Wheel positioning mechanism To enable the load handling device 130 to move in the first and second directions on different wheels 135, 136, the load handling device 130 includes a wheel positioning mechanism or a direction changing mechanism for selectively engaging either the first set 135 of wheels with the first set 22a of the truck or the second set 136 of wheels with the second set 22b of the truck. The wheel positioning mechanism is configured to raise and lower at least one set 135, 136 of the wheels relative to the open frame structure 131 of the load handling device 130, whereby the load handling device 130 can be selectively moved in either the first or second direction across the tracks of the grid frame structure 1.

[0069] The wheel positioning mechanism may include one or more linear actuators, rotary components, or other means for raising and lowering at least one set 135, 136 of the wheels relative to the open frame structure 131 of the load handling device 130 to move at least one set 135, 136 of the wheels out of and into contact with the truck. In some examples, only one set of wheels is configured to be raised and lowered, and the act of lowering one set of wheels can effectively lift the other set of wheels away from the corresponding truck, while the act of raising a set of wheels can effectively lower the other set of wheels into contact with the corresponding truck. In other examples, both sets of wheels can be raised and lowered, which advantageously keeps the body or the open frame structure 131 of the load handling device 130 at substantially the same height, meaning that the weight of the body or the open frame structure 131 and the components mounted thereon does not need to be lifted and lowered by the wheel positioning mechanism.

[0070] In certain embodiments of the present invention, the wheel positioning mechanism includes cam mechanisms 152 on each side of the load handling device 130. In FIGS. 7 and 15, a cam mechanism 152 is shown on the visible X-direction side, and a similar cam mechanism 152 is disposed on the opposite X-direction side (not shown). Similarly, a cam mechanism 152 is shown on the visible y-direction side, and a similar cam mechanism 152 is disposed on the opposite y-direction side (not shown). In other words, the cam mechanisms 152 on each side of the load handling device 130 are configured to raise and lower pairs of wheels relative to the open frame structure 131 of the load handling device 130. Each cam mechanism 152 on opposite sides of the load handling device is configured to synchronously raise and lower corresponding pairs of wheels of the first set 135 of wheels or the second set 136 of wheels relative to the open frame structure 131 of the load handling device 130 to move the load handling device in the X-direction or the Y-direction on the grid structure. Specifically, the cam mechanism 152 includes a cam 154 having a cam profile 156 and a cam follower 158 engageable with the cam profile 156. In a particular embodiment of the present invention shown in FIG. 7, the cam follower 158 is a roller that rotates freely about a rotating shaft or a spigot. The cam follower 158 is configured to move along the longitudinal direction of the cam profile 156.

[0071] The cam 154 comprises a slot having a profile 156 that extends longitudinally along the slot between a first limit or lower limit 160 (valley) and a second limit or upper limit 162 (crest). Between the limits, the slot extends substantially horizontally from the lower limit 160, slopes upwardly, and then continues substantially horizontally to the upper limit 162 with sufficient space to accommodate the cam follower 158. The movement of the cam follower 158 from the lower limit 160 to the upper limit 162 causes one or more wheels of the first set 135 of wheels or the second set 136 of wheels to move in an upward direction to disengage from the track. Similarly, the movement of the cam follower 158 from the upper limit 162 to the lower limit 160 causes one or more wheels of the first set 135 of wheels or the second set 136 of wheels to move in a downward direction to engage with the track. One or more wheels of the first set 135 of wheels or the second set 136 of wheels may be coupled to either the cam 154 or the cam follower 156 via their corresponding wheel attachments such that movement of the cam follower 156 relative to the cam 154 causes one or more wheels of the first set 135 of wheels or the second set 136 of wheels to descend or ascend.

[0072] A pair of wheels on one side of the load handling device can share the same cam and cam follower such that movement of the cam follower along the cam simultaneously raises or lowers the pair of wheels. A pair of wheels on opposite sides of the load handling device represents a first set of wheels for moving the load handling device in the X direction, and a pair of wheels on the other opposite sides of the load handling device represents a second set of wheels for moving the load handling device in the Y direction. In other words, this cam mechanism provides a single cam configuration such that a pair of wheels on the side of the load handling device of the first set of wheels or the second set of wheels is lowered or raised by the same cam and cam follower. However, in a particular embodiment of the present invention shown in FIG. 7, the cam mechanism 152 employs a dual cam configuration rather than a single cam configuration on each side of the load handling device. The first cam and the second cam are arranged adjacent to each other in the horizontal direction. The first cam profile and the second cam profile are substantially identical. Similarly, a pair of followers is arranged to engage the corresponding cam. Instead of a single cam configuration for raising and lowering the pair of wheels, the dual cam configuration on one side of the load handling device in this case provides movement of the pair of wheels on one side of the load handling device in the raised and lowered positions. Using a dual cam configuration rather than a single cam configuration on each side of the load handling device maintains the horizontal orientation of the pair of wheels of the first set of wheels or the second set of wheels during movement in the raised or lowered position. However, the cam mechanism is not limited to a dual cam configuration on each side of the load handling device and may comprise a single cam configuration on each side of the load handling device.

[0073] In order to move the cam follower 158 relative to the cam 154, in a particular embodiment of the present invention, the cam mechanism 152 comprises a traveler 164 configured to move along a side of the load handling device. The traveler 164 is coupled to a cam follower 158 such that movement of the traveler 164 along one side of the load handling device 130 causes one or more wheels of the first set 135 of wheels or the second set 136 of wheels to be raised or lowered. The traveler 164 may be configured to move along rails 166 (see FIG. 8) on each side of the load handling device such that movement of the traveler 164 along the rails 166 causes the cam follower 158 to move along the cam 154, which in turn raises a pair of wheels of the first set or the second set of wheels when the cam follower is at the upper limit 162 of the cam 154 and lowers one or more wheels when the cam follower is at the lower limit 160 of the cam 154. In a particular example of the present invention, the rails 166 for supporting the traveler 164 are integrally formed from the open frame structure 131 of the load handling device 130, and more particularly from one of the modular sub-frames of the open frame structure.

[0074] The traveler 164 is configured to move along the rail 166 by a cam drive mechanism comprising a cam motor 168 coupled to the traveler 164 via one or more pulleys, spools, belts, and / or gears to move the traveler along one side of the load handling device. In a particular embodiment of the invention, the motor 168 is configured to move the traveler 164 along one side of the load handling device by a cam belt 170 having one end moored to the cam motor 168 and the other end moored to the traveler 164. The cam belt 170 is wound around a cam spool attached to the drive shaft of the cam motor 168 such that rotation of the cam spool by the cam motor 168 applies a tensile force to the cam belt 170, which in turn moves the traveler 164 moored to the cam belt 170 along the rail 166. To return the traveler 164 to its initial position, a second motor can apply an opposing tensile force to the traveler 164 to pull the traveler 164 in the opposite direction. Alternatively, the traveler can be biased by a biasing force (e.g., a spring) towards a first position corresponding to the lower or upper limit of the cam profile, and the motor is configured to apply a tensile force to the traveler that resists the biasing force to move the traveler towards a second position corresponding to the upper or lower limit of the cam profile. To provide the mooring necessary to raise and lower a pair of wheels relative to the open frame structure of the load handling device, the cam motor 168 is preferably attached to the open frame structure 131.

[0075] To provide synchronized movement of a first set of wheels or a second set of wheels that move in the X or Y direction over a lattice structure, corresponding traversers for the first set of wheels or the second set of wheels on opposite sides of a load handling device can be moved by one or more cam motors. For example, a single cam motor can provide a tensile force for raising or lowering the first set of wheels 135. Similarly, a single cam motor can provide a tensile force for raising or lowering the second set of wheels 136. Alternatively, two cam motors can apply tensile forces opposite to each other to the traverser to raise and lower corresponding pairs of wheels of the first set of wheels or the second set of wheels. In a particular example of the invention shown in FIG. 7, two cam motors are used to synchronously raise and lower the first set of wheels and the second set of wheels. To provide synchronized movement of the first set of wheels and the second set of wheels, each of the two cam motors is configured to rotate in both the clockwise and counterclockwise directions. A plurality of cam belts 170 are wound around or extend around the outer edge or periphery of the open frame structure 131 of the load handling device 130 via connections to the traverser and the cam motor 168 such that clockwise rotation of the two cam motors raises the first set of wheels 135 and lowers the second set of wheels 136. Conversely, counterclockwise rotation of the two cam motors 168 raises the first set of wheels 135 and lowers the second set of wheels 136.

[0076] A specific example of the wheel positioning mechanism shown in FIG. 7 comprises a cam mechanism driven by a cam motor, but in the present invention, other configurations of the wheel positioning mechanism are applicable. For example, the wheel positioning mechanism may comprise a compliant mechanism having at least one elastically deformable member configured to move by a force applied, e.g., by a motor, to raise or lower the wheels, as taught in PCT Application No. PCT / EP2021 / 055335 in the name of Ocado Innovation, the details of which are incorporated herein by reference. Specifically, the first set of wheels or the second set of wheels may be raised away from the rail or lowered onto the track or rail by a set of compliant or coupling mechanisms attached to an open frame structure on opposite sides of the load handling device.

[0077] The compliant mechanism for changing direction is deformable in the first and second directions respectively. When there is no input, the compliant mechanism is stationary or in a neutral position, i.e., the compliant mechanism is not elastically deformed, both sets of wheels are at the same level, and are stationary on a surface. In this configuration, the load handling device cannot move in either the x-direction or the y-direction, and the load handling device is stationary. The elastic deformation of the compliant mechanism is linked to the arms holding each of the wheels, which are movable in the vertical (i.e., z) direction to raise or lower the wheels.

[0078] When a first input F1 is applied, the compliant mechanism body deforms in the first direction. The displacement of the mechanism body is converted in the vertical direction to lower the first set 135 of wheels and raise the second set 136 of wheels. The wheels of the first set of wheels move downward to engage the rail or track and support the transport means, and the wheels of the second set of wheels move upward to move away from the track. As a result, the load handling device 130 can be driven in the X direction.

[0079] When a second input F2 is applied in a direction opposite to the first input, the compliant mechanism body deforms in a second direction. The displacement of the mechanism body is converted to operate in the vertical direction in order to raise the first set 135 of wheels and lower the second set 136 of wheels so that the load handling device can be supported by the second set 118 of wheels and driven in the y direction.

[0080] The compliant mechanism is connected to the sets 135, 136 of wheels via a transmission linkage mechanism. Thus, in this way, the compliant mechanism provides a means for changing the operating travel direction of the load handling device 130.

[0081] Container lifting mechanism To remove a storage container stored within a lattice framework structure, the load handling device comprises a container lifting mechanism or container lifting assembly comprising a grapple device or container gripper assembly 172 for releasably gripping the storage container from the stack and lifting the storage container into the container receiving space of the load handling device (see Figure 6). A winch assembly or crane assembly is used that comprises a plurality of lifting tethers wound around separate spools, one end of which is fixed to the grapple device, to lift and lower the grapple device. The container receiving space is sized to accommodate the dimensions of the storage container. The container receiving space may be within the open frame structure of the load handling device as shown in Figure 7, or may be adjacent to the open frame structure by a cantilever configuration that balances the weight of the components housed within the open frame structure with the weight of the storage container that is to be lifted by the container lifting mechanism.

[0082] As shown in FIG. 6, the grapple device 172 is formed as a frame having four corner sections, an upper surface, and a lower surface. The lifting mechanism is used to lift the container into the container receiving space of the load handling device. To maximize stability and load capacity, typically four lifting tethers 38 (see FIG. 5b) are used to winch the grapple device 172, in which case one tether is disposed near or at each of the corners of the grapple device 172, although if desired, different configurations can be used, for example with fewer tethers. One end of each of the tethers, e.g., the first end, is wound around a spool within the load handling device, and the other end, e.g., the second end, is typically fixed to the grapple device 172 by appropriate brackets (not shown) at each corner of the grapple device. The number of tethers attached to the grapple device is determined by the ability to keep the grapple device horizontal during operation when picking up the container 10 and the ability to withstand, without stretching or elongating, the tension applied to the tethers when lifting a container that can weigh up to 40 kg, i.e., not to stretch under a given tensile stress applied. To have the required physical characteristics (Young's modulus), the tethers are generally in the form of cables, e.g., ropes or even tapes, although in the present invention other tethers having the physical characteristics required for winching the container are acceptable.

[0083] To grip the container 10, the grapple device 172 includes four positioning pins or guide pins 174 near or at each corner of the grapple device 172 that mate with corresponding notches or holes formed in the four corners of the container 10, and four gripper elements 176 disposed on the bottom surface of the grapple device 172 to engage the rim of the container. The positioning pins 172 help to properly align the gripper elements 176 with corresponding holes in the rim of the container.

[0084] Each of the gripper elements 176 is foldable to be receivable within a corresponding hole in the rim of the container and has an open expanded configuration with at least one dimension larger than the holes in the rim of the container so as to lock onto the container, and comprises a pair of wings 178. The wings 178 can be driven by a drive gear into an open configuration. More specifically, at least one head of the wings comprises a plurality of teeth that mesh with the drive gear such that rotation of the drive gear rotates the pair of wings from a folded configuration to an open expanded configuration when the gripper element 176 is actuated.

[0085] When in a folded or closed configuration, the gripper element 176 is sized to be receivable within a corresponding hole in the rim of the container. Each foot of the pair of wings comprises a stop, for example a boss, such that when received within a corresponding hole in the rim of the container to lock onto the container when the grapple device 172 is winched upwardly towards the container receiving portion of the load handling device, the stop 180 engages the lower surface of the rim when in the expanded open configuration.

[0086] Turning to the winch assembly of the container lifting mechanism, the winch assembly comprises a lifting drive mechanism and four tethers wound around four separate spools 182 (a and b) (see FIGS. 7(a) and 7(b)). The four tethers extend downwardly from their respective four spools 182 (a and b) such that the lower end of each tether is connected to the grapple device 172. The four spools 182 (a and b) can be mounted on separate lifting shafts or, alternatively, can be mounted on the same or a common rotatable lifting shaft 183. In the particular embodiment of the invention shown in FIGS. 7(a) and 7(b) as well as FIG. 8a, the raising and lowering mechanism is based on the four separate spools 182 (a and b) being mounted on separate lifting shafts 183 (a and b). More specifically, the four separate spools are divided into a first set of spools 182a and a second set of spools 182b, each of the first set of spools and the second set of spools comprising a pair of spools. The lifting tether 38 wound around the first set of spools 182a is moored to one side of the container gripping assembly 172, and the lifting tether 38 wound around the second set of spools 182b is moored to the other side of the container gripping assembly 172. The first set of spools and the second set of spools are rotatably mounted on separate first and second lifting shafts 183 (a and b). The first and second lifting shafts are spaced apart so as to accommodate at least a portion of the receptacle 138 considered above, i.e., the receptacle is positioned between the first lifting shaft 183a and the second lifting shaft 183b. The first and second lifting shafts 183 (a and b) are shown rotatably mounted in one of the modular sub-frames, more specifically the upper modular sub-frames 134a, b, in FIG. 8(a) and 8(b). In FIG. 8(a) and 8(b), the upper modular sub-frame is defined as the third modular sub-frame 134a, b.

[0087] The first lifting shaft 183a and the second lifting shaft 183b are driven by a lifting drive mechanism to rotate the first set 182a of spools and the second set 182b of spools. In a particular embodiment of the invention, the first lifting shaft 183a and the second lifting shaft 183b are configured to transmit rotation from an output of a single motor to rotate the first set of spools and the second set of spools via a plurality of timing pulleys, timing belts, and / or gears for raising and lowering the container gripper assembly. In a particular embodiment, the first lifting shaft and the second lifting shaft are driven to rotate synchronously by being connected to a single motor via a single timing belt that extends around a first timing pulley and a second timing pulley respectively attached to the first lifting shaft and the second lifting shaft to form an endless loop. The timing belt may be arranged such that the first lifting shaft and the second lifting shaft are connected to the inner surface of the timing belt via their respective first timing pulley and second timing pulley. This has the effect of rotating the first set of spools and the second set of spools in the same rotational direction. Alternatively, the inner surface and the outer surface of the timing belt may be arranged to contact the timing pulleys on the first lifting shaft and the second lifting shaft such that the first timing pulley is connected to the inner surface of the timing belt and the second timing pulley is connected to the outer surface of the timing belt. This has the effect of rotating the first lifting shaft and the second lifting shaft in opposite rotational directions with respect to each other when the single motor rotates, i.e., the first lifting shaft and the second lifting shaft rotate in reverse.

[0088] Alternatively, as taught in PCT / EP2021 / 051531 in the name of Ocado Innovation Limited, the contents of which are incorporated by reference in their entirety, the first set of spools and the second set of spools can be driven to rotate in the same direction as a single motor. In PCT / EP2021 / 051531, the first set of drive pulleys and timing pulleys are attached to a rotatable shaft, and the first set of spools share a common connection to the rotatable shaft such that rotation of the rotatable shaft by a single motor drives the first set of spools via the connection to the drive pulley. The second set of timing pulleys is connected to the first set of timing pulleys via one or more of a plurality of timing belts such that rotation of the rotatable shaft by a single motor drives the second set of spools via the connection to the drive pulley.

[0089] Various mechanisms for coupling a motor to a lifting shaft can be used, including but not limited to at least one of a plurality of timing pulleys, timing belts, and / or gears, to transmit rotation from the output of the motor to the lifting shaft. The present invention is not limited to the container lifting mechanism discussed above with reference to FIG. 6, and in the present invention, other container lifting mechanisms for removing a storage container from the lattice framework structure of the storage and retrieval system are applicable.

[0090] However, in all of the various examples of the winch assembly discussed above, the lifting shaft supporting the plurality of spools is arranged to provide a space or gap for accommodating at least a portion of the receptacle between the first set of spools and the second set of spools. Since the first set of spools and the second set of spools are rotatably attached to at least one of the modular sub-frames, the attachment of the first set of spools and the second set of spools is arranged such that at least a portion of the receptacle extends vertically through at least one of the modular sub-frames.

[0091] Frame structure Returning to the modular structure of the load handling device to accommodate the various functional features of the load handling device shown in FIG. 9a, the different modular sections 132a, 133a, 134a of the load handling device can be envisioned by the structure of the simplified modular blocks 132b, 133b, 134b that form a vertically stacked layered structure shown in FIG. 9b. In a particular embodiment of the present invention, the three modular sections 132(a and b), 133(a and b), 134(a and b) are shown as a vertical stack, and each of the three modular sections provides one or more of the functional features of the load handling device. For the purposes of the description of the present invention, the three modular sections labeled as increasing the height of the load handling device comprise a first, a second, and a third modular section. The first modular section 132(a and b) is at the lower part of the load handling device, and the third modular section 134(a and b) is at the upper part of the load handling device. As shown in FIGS. 8(a and b), each of the three modular sections supports at least a portion of one or more of the functional components of the load handling device. The number and position of the various modular sections within the layered structure are not limited to the three modular sections shown in FIGS. 8(a and b), and may include any number of modular sections that provide additional functional features of the load handling device, or may be shared among any number of modular sections.

[0092] Each modular section may be envisioned as a rectangular open frame formed by connecting or coupling a plurality of corner brackets (see FIG. 9a), with each corner bracket shown as a connection block in FIG. 9b. The modular section is constructed by connecting adjacent connection blocks in the same horizontal plane by one or more connection elements 184 so as to form an open rectangular frame or modular sub-frame 186. Adjacent rectangular frames or modular sub-frames 186 in the vertical direction are thus connected together by connecting adjacent connection blocks 140 in the vertical direction so as to form an open frame structure 131 as shown in FIGS. 8(a and b). An example of the connection block 140 is a corner bracket. In a single modular section, each corner bracket is connected by one or more connection elements 184 to two other corner brackets in the same horizontal plane. The connection element can be a connecting rod or tube for connecting adjacent connection blocks (corner brackets) together in a single modular section. The connecting rod can be solid or hollow and is determined by the connection to the connection block, as further explained below. In a particular embodiment of the present invention, the open frame structure is a three-dimensional structure defining a volume having an upper portion comprising a receptacle 138 (see FIG. 7b), a control unit 144a, spools 182 (a and b) for supporting lifting tethers, and a lower portion comprising a container receiving space 137.

[0093] The structural integrity of the open frame structure should be sufficient not only to support the various functional features of the load handling device, but also to have sufficient bending stiffness when the load handling device is operating on the lattice structure. Various materials can be used to fabricate the connecting rods or connecting tubes. These include, but are not limited to, metals or polymers (e.g., plastics) or ceramics or combinations thereof. Optionally, the connecting rod that connects adjacent corner brackets together to reduce the weight of the load handling device and have the structural features necessary to support the various functional components of the load handling device is composed of carbon fibers hardened in a polymer matrix (known as carbon fiber rods). To assist in constructing the rectangular frames that form the modular sections, each of one or more connection blocks in the modular sections includes an opening or socket 187 (see FIG. 10) for inserting a connecting rod. The connecting rod is fixed to the connection block by a joint. Various joints can be used to fix the connecting rod to the corner brackets in the modular section. These include various fixing means, adhesives, welding, etc.

[0094] A simplified modular section is one in which the connection blocks 140 are corner brackets such that the modular section comprises four corner brackets. As shown in FIG. 8b, each of the four corner brackets is directly connected to two other corner brackets in the same horizontal plane so as to form a simple open rectangular frame or sub-frame. However, the corner brackets in a single modular section can be indirectly connected to two other corner brackets by one or more connection blocks that are intermediate the corner brackets at the corners of the rectangular frame. In this case, the term "connected" with respect to the corner brackets in each of the modular sections can be broadly interpreted to mean being directly and / or indirectly connected to two other corner brackets.

[0095] To construct a load handling device according to the present invention, different modular sections are vertically connected to adjacent rectangular modular sub-frames 186 by one or more vertical continuation elements 188 via their corresponding connection blocks or corner brackets 140 to form an open frame structure 131 as shown in the simplified open frame structures of FIGS. 8a and 8b. In other words, the same corner bracket for connecting to two other corner brackets of a single modular section can be used to vertically connect adjacent rectangular sub-frames. The corner brackets of adjacent rectangular sub-frames in the vertical direction can be attached to the same vertical continuation element 188 at each corner of the open frame structure such that the vertical continuation element extends through the corner brackets of a plurality of vertically adjacent rectangular modular sub-frames. As a result, each corner of the open frame structure shares the same or a common vertical continuation element. To connect a plurality of rectangular sub-frames to the same vertical continuation element at each corner of the open frame structure via their corresponding corner brackets, the corner brackets between the intermediate or bottom rectangular sub-frame and the top rectangular sub-frame have one or more through-holes for the vertical continuation element to extend through the corner brackets when connecting adjacent rectangular sub-frames 186 vertically together (see the second modular section in FIG. 8a). This has the advantage that a plurality of rectangular sub-frames can be vertically connected together as a stack simply by attaching the plurality of rectangular sub-frames to the same vertical continuation element at each corner of the open frame structure to form a load handling device as shown in FIGS. 8(a and b). This is clearly evident in the schematic view of one face of the open frame structure shown in FIG. 16. Here, the vertical continuation element is shown as extending through a plurality of blocks at the corners of the open frame structure.

[0096] Alternatively, separate vertical continuation elements may be used to connect adjacent rectangular sub-frames in the vertical direction at each corner of the open frame structure. The length of the vertical continuation element that connects adjacent rectangular frames in the vertical direction determines the height of the open frame structure. The connecting element 188 that connects adjacent rectangular sub-frames in the vertical direction into one may be of the same type or a different type of connecting element as the connecting element that connects adjacent corner brackets in the same horizontal plane. For example, the connecting element 188 that connects adjacent rectangular frames in the vertical direction into one may be a connecting rod used to connect corner brackets in a single modular section. The connection of corner brackets forming a connection block into one by the horizontal connection rod 184 and the vertical continuation rod 188 is illustrated by pre-assembly of the second modular section shown in FIG. 10, which includes a support or rail 166 for the traveler of the cam mechanism of the wheel positioning mechanism discussed above. A similar process of connecting the connection blocks with horizontal connection rods also applies to the assembly of the first and third modular sections. Each corner bracket or connection block 140 is shaped to receive one or more connection rods or tubes 184, 188 for connecting the connection blocks into one to form a single modular section, and includes one or more sockets 187. Adjacent modular sections in the vertical direction are connected into one as a vertical stack. The arrows in FIG. 10 indicate the direction of the connection rod or tube 184 when inserted into the corresponding socket 187 in the connection block or corner bracket 140.

[0097] While still corresponding to various functional features of the load handling device, in order to simplify the structure of the load handling device, at least a part of the functional components of the load handling device is integrated into the open frame structure 131 of the load handling device 130 in the sense that at least a part of the functional components of the load handling device is integral with one or more of the rectangular frames or modular sub-frames of the load handling device. For example, at least a part of the wheel assembly is integral with one or more modular sub-frames of one or more rectangular frames, at least a part of the wheel drive assembly is integral with one or more modular sub-frames of one or more rectangular frames, at least a part of the wheel positioning mechanism is integral with one or more modular sub-frames of one or more rectangular frames, and / or at least a part of the container lifting mechanism is integral with one or more modular sub-frames of one or more rectangular frames.

[0098] In order to integrate at least a part of the various functional features of the load handling device into one or more of the rectangular frame modular sub-frames that make up the open frame structure of the load handling device, one or more of the connecting blocks 140 of one or more of the rectangular sub-frames 186 are fabricated in consideration of the functional features of the load handling device. At least a part of one or more of the functional components of the load handling device is integrated into one or more of the connecting blocks of one or more rectangular frames. For example, one or more of the corner brackets that connect the rectangular frames together may be formed integrally with one or more mounting parts for a spool, pulley, and / or motor, rather than having a separate mounting part for attachment to the frame of the load handling device.

[0099] Various connection blocks can be used to construct various modular sections, and the selection of the connection blocks greatly depends on various functional features of the load handling device. The shape of the connection blocks becomes more complex as the complexity of the functional features of the load handling device increases. Examples of various connection blocks 140(b~d) in a simplified form forming the corner brackets of an open frame structure are shown in FIGS. 13 to 15, which represent various corner brackets for assembling the rectangular sub-frames of various modular sections of the load handling device, as clearly shown in FIG. 16.

[0100] A variety of lightweight materials can be used to fabricate the connection block. Examples of lightweight materials include, but are not limited to, various lightweight metals such as aluminum, or various polymer materials such as plastic materials, or composite materials (such as carbon fiber / polymer composites). A variety of methods can be used to fabricate the connection block. These include, but are not limited to, machining from a block, injection molding, or casting. However, as the complexity of the connection block increases, particularly when at least a portion of the functional components of the load handling device are integrated with connection blocks 140, 140(b - d), more sophisticated fabrication methods can be used. The use of additive manufacturing such as 3D printing provides the ability to fabricate complex connection blocks such that at least a portion of the functional components of the load handling device can be formed integrally with one or more connection blocks. Using additive manufacturing for fabricating connection blocks, particularly corner brackets, enables one or more of the connection blocks to be topologically optimized considering the stresses that the connection blocks are expected to receive in an open frame structure. This is because additive manufacturing or 3D printing has the ability to form complex shapes that cannot be achieved by machining alone. This is particularly true when the connection block is topologically optimized, as the results of topological optimization tend to result in complex shapes in order to account for the various load constraints that the connection blocks are likely to encounter when applied to the open frame structure of the load handling device.

[0101] In the bottom or first modular section, the wheels of the wheel assembly are supported by a rectangular modular subframe 186. In order to accommodate the wheels of the wheel assembly, each of the connection blocks, and more particularly the corner brackets, of the bottom or first modular section is integrally formed with one or more wheel attachments 139, 141 for a first set of wheels and a second set of wheels. In a particular embodiment of the invention shown in FIG. 15, each of the corner brackets 140d of the bottom modular section is formed in two parts to accommodate two wheel attachments, namely a first wheel attachment 139 and a second wheel attachment 141. The first wheel attachment 139 is configured to attach the wheels of the first set 135 of wheels, and the second wheel attachment 141 is configured to attach the wheels of the second set 136 of wheels (in which case there are a total of eight wheels attached to four corner brackets 140d and arranged to support the open frame structure of the load handling device, with two wheel attachments for each of the four corner brackets 140d). In other words, each of the four corner brackets 140d of the first or bottom modular section is integrally formed with two wheel attachments, namely a first wheel attachment 139 and a second wheel attachment 141. In order to accommodate two wheel attachments within one corner bracket 140d, the two wheel attachments of a given corner bracket are assembled substantially perpendicular to each other such that the first wheel attachment 139 provides an attachment for the wheels for moving the load handling device in a first direction and the second wheel attachment 141 provides an attachment for moving the load handling device in a substantially perpendicular direction. In a particular embodiment of the invention shown in FIGS. 9a and 15, the first wheel attachment 139 and the second wheel attachment 141 of the corner bracket comprise a shaft or spigot 198 for rotatably attaching the corresponding wheels.

[0102] As further shown in FIG. 9a and more clearly shown in FIG. 15, each edge or end of the first wheel attachment portion and the second wheel attachment portion of a given corner bracket 140d includes one or more bosses or fingers 196 having openings that are vertically aligned or concentric for receiving a connection element 188 through the openings of the one or more bosses 196. The one or more bosses 196 at the edges of the first wheel attachment portion 139 and the second wheel attachment portion 141 are spaced apart such that the bosses 196 of both the first wheel attachment portion and the second wheel attachment portion of a given corner bracket are combined with each other, and such that the openings in their corresponding bosses receive the connection element 188 when, as shown in FIG. 16, the bottom or first modular section is vertically connected to the second modular section directly above it, with the openings in the corresponding bosses being axially aligned along the wheel positioning axis W-W (see FIG. 15). The wheel positioning axis W-W is the axis along which a first set of corresponding wheels or a second set of wheels is raised or lowered depending on the direction of movement on the lattice structure. In FIG. 15, the wheel positioning axis W-W is shown as the vertical axis along which the first set of wheels and the second set of wheels are raised and lowered.

[0103] In operation, the first wheel attachment portion and the second wheel attachment portion are arranged to move along a common vertical continuation element via their corresponding bosses. For a given corner bracket, the bosses 196 at the edges of the first wheel attachment portion 139 and the second wheel attachment portion 141 of the corner bracket 140d are sufficiently spaced such that when the spaced bosses are combined with each other, each of the first wheel attachment portion 139 or the second wheel attachment portion 141 of the corner bracket 140e can move independently of the other second wheel attachment portion 141 or the first wheel attachment portion 139 along its vertical continuation element, i.e., along the wheel positioning axis W-W. This enables a pair of the first set of wheels to be raised or lowered independently of a pair of the second set of wheels when attached to the corner bracket. This is repeated for the other corner brackets of the bottom modular section such that all four corner brackets of the bottom modular section provide wheel attachment portions for supporting all of the wheels of the first set and the second set of wheels, i.e., eight wheels. To enable the first wheel attachment portion and the second wheel attachment portion to move along the vertical continuation element, the bosses 196 at the edges of the first wheel attachment portion and the second wheel attachment portion may comprise one or more sliding bearings for assisting the movement of the first wheel attachment portion and the second wheel attachment portion along their corresponding vertical continuation element. Various sliding bearings known in the art may be used to assist the sliding of the first wheel attachment portion and the second wheel attachment portion. These include, but are not limited to, the use of PTFE-based sliding bearings.

[0104] Each of the wheel attachment portions of the corner brackets includes an integrally formed wheel shaft 198 for rotatably attaching a wheel onto a shaft. Each corner bracket 140d for attaching a wheel of the wheel assembly is connected to two other corner brackets by one or more connecting elements 184 so as to form a rectangular sub-frame. In a particular example of the invention shown in FIGS. 8a and 9a, each of the corner brackets 140d is connected to two other corner brackets in the same horizontal plane by two connecting rods 184 that are receivable within an opening or socket 187 (see FIG. 16) of the corner bracket. However, the number of connecting elements 184 for connecting adjacent corner brackets in the same horizontal plane so as to form a rectangular frame of a first modular section comprising the wheel assembly is not limited to two connecting elements and can be any number of connecting elements for providing the required structural rigidity of the rectangular frame.

[0105] To drive the rotation of the first set of wheels and the second set of wheels, at least a portion of the wheel drive assembly discussed above can be integrated into one or more of the rectangular sub-frames of the open frame structure of the load handling device. When the wheel drive assembly includes the drive belt assemblies 143a on each side of the load handling device discussed above, the mounting portions for the drive wheels and the driven wheels for supporting the drive belt can be integrally formed with one or more of the connection blocks 140d (see FIG. 15) of one or more of the rectangular sub-frames. For example, in a particular embodiment of the present invention shown in FIG. 15, each of the corner brackets 140d including the wheel mounting portions 139, 141 for the wheel assembly further includes a mounting portion 200 for the driven wheel of the drive belt assembly such that the drive belt travels around the outer edges of the wheels 135, 136 attached to the corner bracket 140d and around the driven wheel 148 on the same corner bracket 140d (see FIGS. 7 and 15). Since each corner bracket 140d is integrally formed with the two wheel mounting portions 139, 141 for the wheels oriented orthogonal to each other so as to cover the travel direction of the load handling device on the lattice structure, the corresponding mounting portion 200 for the driven wheel can be integrally formed with each of the wheel mounting portions 139, 141 of the corner bracket 140d.

[0106] The drive pulley for driving the rotation of the pair of wheels of the first set of wheels or the second set of wheels is positioned at a higher position in the vertical stack such that the drive belt extends around the pair of wheels on one side of the load handling device and around the drive wheel attached to the higher modular section. It is attached to the corner bracket 140c of the rectangular sub-frame. In a particular embodiment of the present invention, the drive wheel for driving the drive belt of each wheel drive assembly is attached to a shaft or spigot 202 integrally formed with the corner bracket 140c that forms the rectangular sub-frame of the second modular section. As a result, each pair of wheels of the first set of wheels and the second set of wheels is driven by a drive belt that connects the driven wheel in the first modular section 132a and the drive wheel attached to the corner bracket of the second modular section 133a. This is repeated for the other drive assemblies on each side of the load handling device, as shown in FIG. 7. Also shown in FIG. 7 is that each wheel drive assembly for driving a pair of wheels additionally comprises the tensioning wheel configuration discussed above to ensure that the drive belt around the given pair of wheels remains taut. In the particular example of the load handling device shown in FIG. 7, one or more of the corner brackets of the rectangular frame supporting the wheels also comprise a wheel tensioning configuration.

[0107] The drive assembly is not limited to the drive belt assembly discussed above, and the connection blocks of the rectangular frame that supports the wheels of the wheel assembly can be integrated with the attachment portions for supporting the hub motor discussed above. In this case, each corner bracket of the rectangular frame of the first or bottom modular section can be formed integrally with an attachment portion for a drive assembly including a hub motor, and in this case, the inner hub of the hub motor is attached to the corner bracket. Each of the corner brackets of the first or bottom modular section is formed with two wheel attachment portions for attaching two wheels, so each corner bracket is formed integrally with two attachment portions for attaching two hub motors, one for attaching a wheel in a first direction and the other for attaching a wheel in a second direction.

[0108] To change direction on the grid structure, the load handling device comprises a wheel positioning mechanism. Various wheel positioning mechanisms are known in the art, some of which have been discussed above. Considering that sufficient force is required to lift a given pair of wheels perpendicular to the open frame structure, at least a portion of the wheel positioning mechanism is attached to a rectangular sub-frame of the open frame structure that is reinforced to withstand the weight of the pair of wheels on each side of the load handling device. In a particular example of the load handling device shown in FIGS. 7 and 10, the rectangular sub-frame of the second modular section is reinforced by one or more struts or braces 206 and is positioned substantially midway in the height of the load handling device, i.e., between the first modular sub-frame and the third modular sub-frame, and is thus referred to as the "middle halo" (see FIG. 8a). The middle halo is reinforced by one or more cross braces 206 extending across the rectangular frame. A particular example of the wheel positioning mechanism shown in FIG. 7 is based on the cam mechanism discussed above, comprising a cam, a cam follower movable along the cam, and a traveler for moving the cam follower. The traveler is configured to move along a rail 166 on one side of the load handling device to raise the pair of wheels. The rail 166 for supporting the traveler to raise the pair of wheels extends between corner brackets of the rectangular frame of the middle halo such that the traveler moves along a connecting element 184 connecting corner brackets 140 on one side of the load handling device and comprises a horizontal connecting element. The connecting element for supporting the traveler of the middle halo functions as an overhead rail in this case. In a particular example of the invention shown in FIG. 7, the traveler is slidably attached to a connecting element connecting corner brackets in the same horizontal plane. This is repeated for the other pairs of wheels on each side of the load handling device. At least two connecting elements 184 extend between corner brackets 140 on one side of the load handling device to support the traveler.To prevent the connecting element from bending excessively when the traveler moves along the connecting element, one or more inserts 208 are sandwiched between two connecting elements 184 extending between the corner brackets 140 to provide bending rigidity to the connecting element extending between the corner brackets 140. In a particular example of the present invention, each cam mechanism of the pair of wheels of the first set of wheels and the second set of wheels is based on a double-cam configuration as discussed above, where the traveler is configured to raise and lower a given set of wheels via the double-cam configuration. The cam for cooperating with the cam follower can be attached to the corner bracket that supports the wheel of the wheel assembly or can be formed integrally with the corner bracket. In the double-cam configuration on each side of the load handling device, two cams 154 are attached to each corner bracket to cooperate with two corresponding cam followers to correspond to the vertical movement of the wheels in the first direction and the second direction (see FIG. 15). In this case, with respect to a given corner bracket, when both the first wheel attachment portion and the second wheel attachment portion of the corner bracket are considered together, the cams 154 on different sides of the load handling device cooperate with their corresponding cam followers such that the first cam 154 is attached to or formed integrally with the first wheel attachment portion 139 of the corner bracket, and the second cam 154 is attached to or formed integrally with the second wheel attachment portion 141 of the corner bracket 140d. Similar corner brackets are used for the attachment of the other wheels of the wheel assembly.

[0109] As the cam follower travels along the cam, an upward or downward force is applied to the corresponding corner bracket that supports the first set of wheels or the second set of wheels, which raises or lowers the wheels depending on the direction of travel of the load handling device on the lattice structure. As discussed above, each corner bracket for attaching the wheels of the wheel assembly is formed from two combined parts, namely a first part 139 and a second part 141, and each of the first part and the second part comprises a wheel mounting portion for the wheel. A first portion providing a wheel mounting portion for the first set of wheels and a second portion providing a wheel mounting portion for the second set of wheels are defined as a first wheel mounting portion 139 and a second wheel mounting portion 141, respectively. The bosses or fingers 196 at the edges of the first wheel mounting portion and the second wheel mounting portion are sufficiently spaced apart so that when the bosses are combined with each other, the first wheel mounting portion can move axially along its connecting vertical continuation element independently of the second wheel mounting portion. When the vertical continuation element is a connecting rod, the diameter of the opening in one or more of the bosses 196 of each of the first wheel mounting portion 139 and the second wheel mounting portion 141 of the corner bracket is slightly larger than the diameter of the connecting rod 188 so that the first wheel mounting portion 139 and the second wheel mounting portion 141 of the corner bracket can move vertically when a vertical force is applied. The cam 154 for cooperating with the cam follower 158 can be integrally formed with its corresponding corner bracket 140d having a wheel mounting portion of the wheel assembly as shown in FIG. 15. Two cams 154 are shown integrally formed with the corner bracket 140e, one for each of the wheel mounting portions 139, 141. As can be understood from the above description related to FIGS. 6 and 15, at least a part of the wheel positioning mechanism is integrally formed with a connection block of one or more rectangular sub-frames forming various modular sections of the load handling device, more particularly with the corner bracket.

[0110] Also shown in FIG. 7 is that a motor 168 for moving the traverser along the connecting element is attached to a corner bracket 140c of a rectangular frame forming an intermediate halo of the open frame structure. One or more attachment portions for one or more motors are integrally formed with the connection block and, more particularly, with the corner bracket of the rectangular frame of the intermediate halo. As shown in FIG. 14, one or more openings 210 for receiving the motor shaft of the motor are integrally formed in the corner bracket 140c. The corner bracket 140c also supports a spool for winding a belt connected to the traverser as the spool rotates such that the belt is wound around the spool when the motor rotates in the clockwise direction and the belt is unwound from the spool when the motor rotates in the counterclockwise direction.

[0111] In addition to at least a part of the wheel positioning mechanism being integrally formed with a connecting block or a corner bracket that forms a rectangular sub-frame of one or more modular sections, at least a part of the container lifting mechanism, more specifically the winch assembly, is integrally formed with a rectangular frame of one or more modular sections. A first lifting shaft and a second lifting shaft 183(a and b) for driving the rotation of four spools that support a lifting tether connected to a grappling device are rotatably attached to a rectangular sub-frame of a modular section. In the example shown in FIG. 8a, the first lifting shaft and the second lifting shaft 183(a and b) are rotatably attached to a rectangular sub-frame of the third modular sections 134a, b, c. The first lifting shaft and the second lifting shaft 183(a and b) are shown as extending across the rectangular sub-frame in FIGS. 8a and 9a. The first lifting shaft and the second lifting shaft are substantially parallel and spaced apart so as to define a space for accommodating a receptacle. Both ends of the first lifting shaft and the second lifting shaft are rotatably attached to a corresponding connecting block 140b through a shaft opening 212 in a connecting block as shown in FIG. 13. The shaft opening 212 in the connecting block is sized to rotatably receive the ends of the lifting shafts 183(a and b). Bearings may be incorporated into the shaft opening 212 for attachment to the ends of the lifting shafts 183(a and b).

[0112] In certain embodiments of the present invention, a container receiving space 137 (see FIG. 9a) for receiving a storage container when the storage container is lifted by a grapple device is housed within the open frame structure of the load handling device, and more particularly, within the area of the first, second, and third modular sections (the third modular section supports a spool that supports a lifting tether). However, since the vertically adjacent modular sections are connected together by their corresponding connection blocks via vertical continuation rods, it is necessary to guide the grapple device when the grapple device is lifted into or lowered out of the container receiving space so that the grapple device does not hit the connection blocks. In certain embodiments of the present invention, the connection block 140c of the second modular section of the load handling device has downwardly extending guides (not shown), one for each corner of the rectangular frame, for guiding the grapple device when the grapple device is lowered or raised into the container receiving space 137. Each of the guides extends downwardly inside the container receiving space and is shaped to consist of two vertical guide plates for receiving the corners of the grapple device shown in FIG. 6.

[0113] The container lifting mechanism is configured to lift and lower a storage container that can have a weight of up to 40 kg, and the connection element extending between the corner brackets can be cross-braced by one or more cross-brace elements 206 to reinforce the rectangular frame of the modular section that supports the spool that supports the lifting tether.

[0114] The plurality of rectangular frames 186 are assembled together as a vertical stack to provide the various functional features of the load handling device discussed above. To form an open frame structure 131 that supports the various functional features of the load handling device, adjacent rectangular frames in the vertical direction are connected together by vertical continuation elements 188. The receptacle 138 for receiving power is attached in FIGS. 8(a and b) to the cross brace 206 of the second modular section and is shown as extending upwardly from the open frame structure such that the receptacle 138 extends vertically through at least one of the plurality of modular sub-frames 186. The receptacle 138 is arranged to form a housing having an open upper end for vertically receiving and housing power from above the receptacle and includes a base and side walls / end walls extending upwardly from the base. To ensure that the receptacle 138 does not significantly increase the weight of the load handling device, similar to the structure of the open frame structure 131, the receptacle 138 is shown as having a structure like a frame made from a plurality of connection blocks connected together by a plurality of connection elements so as to define a power section for receiving power. The more simplified structure of the receptacle 138 in FIGS. 8(a and b) shows that the receptacle comprises eight connection blocks, each of the eight connection blocks being connected to two other connection blocks in the same horizontal plane by one or more horizontal connection elements and to one other connection block in a vertical plane by one or more vertical continuation elements so as to form a cuboid frame structure. As discussed above, the receptacle 138 comprises one or more electrical connectors or charge receiving elements configured to electrically couple to the charge supply elements of the power source when the power source is lowered into the receptacle. The electrical connectors of the power section may comprise male connectors, the electrical connectors of the power source may comprise female connectors, or vice versa. The electrical connectors may alternatively comprise electrical contacts.

[0115] The receptacle 138 is depicted as having a cuboid shape in FIG. 11, but other shapes such as a cylindrical shape are possible and highly dependent on the shape of the power source. The receptacle 138 has an open upper end 214 for receiving the power source substantially in the vertical direction (see FIG. 7b). The open upper end 214 is shown as comprising four connection blocks or brackets 216, and each of the four connection blocks 216 is connected to two other connection blocks 216 by horizontal connection elements 218 so as to form a substantially rectangular open frame for receiving the power source. To support the power source, the receptacle 138 comprises a base 220 sized to accommodate the power source when placed within the receptacle 138. Vertical connection elements 222, one end of which is connected to a corner of the base 220 via a suitable opening or socket in the base and the other end of which is connected to the rectangular open frame, extend upward from the base 220. The base 220 optionally comprises charge receiving elements for electrically coupling to the charge supply elements of the power source when the power source is placed on the base 220. The structure of the receptacle 138 is not limited to the open structures shown in FIGS. 8(a and b), FIGS. 9(a and b), FIG. 11, and FIG. 12, and the side walls of the receptacle can be solid to form a housing. For example, as shown in FIG. 11b, the receptacle 338 can be made of metal, such as aluminum, steel, etc. The advantage of using metal among the materials in the fabrication of the receptacle is that electromagnetic signals emitted from the power source 138b and / or the battery management system are prevented from interfering with signals from one or more electronic components essential for the operation of the payload handling device, such as the control device 144a, the communication module 144b, and the J-Switch 144c (see FIGS. 7 and 12), i.e., it functions as a Faraday cage and shield.

[0116] Various methods can be used to fabricate the metal receptacle. These include, but are not limited to, casting, folding of blanks of metal sheets, and the like. In a preferred embodiment, the receptacle is formed by folding a blank of a metal sheet along one or more fold lines so as to form a battery box 340 having a bottom wall (or base) and upwardly rising side walls and end walls. Alternatively, the bottom wall and / or the upwardly rising side walls and / or end walls can be separately integrally fixed by various fixing means. Examples of fixing means include, but are not limited to, riveting, welding, adhesives, and / or simple bolts. In order to reduce the weight of the receptacle and still function as a Faraday cage, the upwardly rising walls and / or end walls are provided with one or more openings 342. The openings can be cut into the upwardly rising walls and / or end walls of the battery box 340 and can be sized to block electromagnetic waves emitted from a power source housed within the receptacle. Fabricating the receptacle from metal, preferably a metal sheet, not only helps reduce or block interference signals from the power source 138b, but also provides a continuous guide surface for guiding the power source 138b into the receptacle 338 when it is lowered through the open upper end 314 of the receptacle. This helps properly guide the power source 138 to engage with the electrical connector. To assist in guiding the power source 138b into the receptacle, the power source 138b is provided with one or more guide members 344 configured to cooperate in a sliding relationship with the corners of the receptacle. Since the receptacle has a rectangular parallelepiped shape, the guide members 344 are attached to the corners of the power source. To assist in positioning the power source within the receptacles 138, 338, each of the guide members 334 is provided with a positioning portion 346. In a particular embodiment of the present invention, a portion of the guide member 344 is chambered or tapered to form a positioning portion 346 for properly positioning the power source 138b within the receptacles 138, 338.Providing a continuous guide surface at the corner of the battery box 340, as compared to forming a receptacle from a plurality of connection blocks connected by a plurality of connection elements, enables the power supply to descend into the receptacle 338 with little or no resistance.

[0117] Since the power supply is housed within the receptacle 138, one or more electrical components that receive power from the power supply, such as a control unit, a communication module, and a J-Switch, are shown in FIG. 12 attached to the receptacle 138, and more particularly, to one or more outsides of the receptacle 138. Signals generated by the one or more electrical components are supplied from their corresponding electrical components, via one or more cables, to various components of the load handling device, namely, motors for driving wheels, a wheel positioning mechanism, and / or a drive mechanism for a container lifting mechanism. To prevent one or more of the cables from catching on one or more of the moving components of the load handling device, the receptacle 138 is provided with a cable tray 224 for guiding one or more cables to their associated components within the load handling device, such as a motor, and for supporting one or more cables. One or more cable retainers 226 (such as cable ties) may be used to secure the cables to the cable tray 224. The cable tray 224 is shown as having a plurality of holes for holding the cables in the cable tray 224, sized to engage a plurality of mooring elements (not shown) of the cable retainer 226. The cable tray 224 is a plate having one or more bends for guiding one or more cables from the electrical components attached to the receptacle 138 to drive their corresponding components within the load handling device.

[0118] In addition to or as an alternative to the cable tray, one or more cables may be secured to the frame or frame structure 231 of the load handling device. In the example shown in FIG. 12d and clearly shown in FIGS. 12e and 12f, the cable attachment portion 356 includes one or more cable holders 326 for securing one or more cables to the cable attachment portion 356, and the cable attachment portion 356 is attachable to at least the modular sub-frame. The cable attachment portion provides an area on the frame 231 for securing one or more cables to the frame itself. The example shown in FIG. 12d shows that the cable attachment portion 356 is attached to the horizontal connecting element 184 of the third modular section 134a of the frame by a snap-fit joint 358. A part of the cable attachment portion has a cross-sectional profile configured to snap onto the horizontal connecting element 184 of the modular sub-frame. In the particular example of the present invention shown in FIGS. 12e and 12f, the snap-fit joint has a substantially semi-circular cross-sectional profile shaped to snap onto the horizontal connecting element 184 of the frame of the load handling device. However, the present invention is not limited to the cable attachment portion being attached to the modular sub-frame by a snap-fit joint, and optionally or additionally, it may be secured to the connection block 140 by fixing means known in the art, such as screws or bolts.

[0119] Figures 12e and 12f also show that each of one or more cable retainers 326 may include a cable tie for securing one or more cables to the cable attachment portion 356. The cable tie may be integrally formed with the cable attachment portion 356 or, alternatively, the cable attachment portion 356 includes an attachment surface having one or more openings for securing the cable tie to the cable attachment portion 356. The advantage of the cable attachment portion compared to the cable tray 224 discussed above is that the cable attachment portion can be attached to any part of the frame due to its snap-fittability onto the connection element 184 of the frame, resulting in the ability to secure one or more cables to various parts of the frame. The cable attachment portion 356 may include one or more branches 360 extending from the snap-fit joint for guiding one or more cables to one or more electrical components located at various parts of the load handling device. The one or more branches 360 may include one or more cable retainers 326 for securing one or more cables to the branches. The cable attachment portion may be integrally formed as a single unit from a plastic material, such as additive manufacturing, injection molding, etc. The plastic material provides electrical insulation and enables integration of the snap-fit joint into the cable attachment portion.

[0120] Considering that the weight of the power supply occupies a significant portion of the weight of the load handling device, in order for the load handling device to withstand the forces resulting from the reaction of the power supply when accelerating on the lattice structure, it is essential that the receptacle be properly fixed to the open frame structure of the load handling device. In a particular embodiment of the present invention, the receptacle 138 is secured to the cross brace 206 of the second modular section 133a. For example, the securing of the receptacle 138 to the open frame structure is provided by cross rib intersection members extending through one or more openings in the base 220 of the receptacle 138. One or more struts 228 may also be used to provide additional support for the receptacle 138 to the open frame structure. In the particular embodiments shown in FIGS. 7, 11, and 12, one or more struts 228 are tethered to form a fixed point on the receptacle 138 and extend to a fixed point on the modular subframe of the second modular section. In the particular embodiment of the present invention shown in FIG. 7, one or more struts are rods or tubes fixed to the horizontal connecting element 218 forming the opening of the receptacle 138 and to a fixed point on the horizontal connecting element of the modular subframe forming the third modular sections 134a, b, c. Alternatively, the receptacle 138 may be integrally formed with at least one of the modular subframes.

[0121] In the case of the receptacle shown in FIG. 11b, the bottom wall of the receptacle 338 comprises attachment feet or brackets 341 for attaching or supporting the receptacle 338 to the cross brace 206 of the second modular section (see FIG. 11b).

[0122] Since the receptacle 138 is exposed above the open framework structure, other electrical components that require direct access from outside the payload handling device can be attached to the receptacle. These include, but are not limited to, various switches and / or power isolators 230 for the power supply. Since the receptacle 138 corresponds to the highest point of the payload handling device, one or more antennas 145 for receiving signals from one or more base stations can be attached to the receptacle 138. In addition to providing one or more attachment points for attaching one or more electrical components, the receptacle can optionally provide an attachment point for a heat sink 348 as shown in FIG. 12b. The heat sink 348 helps keep the one or more electrical components at a low temperature by absorbing and dissipating heat from the one or more electrical components attached to the receptacle.

[0123] The receptacle 138 is not limited to the attachment of one or more electrical components and can be used to provide insulation to a power source. When the power source is a battery, the operating temperature of the battery affects its lifespan. One of the contributing factors to battery heating during charging or discharging is its internal resistance. The higher the internal resistance of the battery, the more heating is caused during charging or discharging, and this heat can cause damage leading to safety issues. A low internal resistance allows the battery to supply large currents on demand, while a high internal resistance causes current limitation and voltage drop across the load. The internal resistance of a battery is highly dependent on temperature and increases as the ambient temperature decreases. This is because low temperature causes a decrease in the rate of the electrochemical reactions occurring within the battery, resulting in a decrease in the mobility of ions in the electrolyte. Since the load handling device may be operable within the chilled zone or freezer zone of the fulfillment center, heating of the battery during charging or discharging of the battery when operable on the lattice structure is causing a shortening of the effective cycle life of the battery and becoming an increasingly significant problem. Optionally, to mitigate the shortening of the battery's service life when the load handling device is operating at a low temperature, e.g., within the chilled zone or freezer zone, the receptacle 138 can be coated with a heat insulation panel to reduce heat loss and assist in maintaining or regulating the temperature within the space occupied by the battery. For example, one or more heat insulation panels can be attached to the outer surface of the receptacle 138 to provide heat insulation to the power source housed within the receptacle 138. Examples of heat insulating materials include, but are not limited to, foams, glass fiber materials containing silica, polyurethanes, etc.

[0124] After the power supply is housed within the receptacle, in order to secure the power supply 138b to the receptacles 138, 338, optionally, the receptacles 138, 338 include a locking mechanism 350 having a locking member 354 movable between a locked position for preventing removal of the power supply from the receptacle and an unlocked position for enabling removal of the power supply from the receptacle (see FIG. 12c). In the particular embodiment of the invention shown in FIGS. 12b and 12c, the locking mechanism includes one or more catching or retaining members 352 formed on the rim of the upwardly rising sidewall and / or endwall of the receptacle 338 that cooperate with a locking member 354 rotatably attached to the power supply. The one or more catching or retaining members 352 may be integrated with the receptacle or may be attached separately to the receptacle. Rotation of the locking member 354 in one direction locks the power supply to the receptacle, and rotation of the locking member in the opposite direction unlocks the power supply from the receptacle. The catching or retaining member 352 shown in FIG. 12b is formed on the rim of the open upper end 314 of the receptacle.

[0125] A particular embodiment of the invention is shown as having an open frame structure for the receptacle 138, but the receptacle is not limited to having an open frame structure and can be in the form of a container having solid sidewalls and a base.

[0126] Manufacture of the frame of the load handling device includes inserting the ends of the connecting rods into openings or sockets in the connecting blocks to connect the connecting blocks together. To assist in reducing the weight of the load handling device according to the invention, the connecting rods are typically hollow, such as hollow pipes. Jigs can be used to assemble the individual rectangular frames together, while the connections between the connecting blocks and / or corner brackets and the connecting elements are ensured by suitable joints. A similar manufacturing process can be used to manufacture the receptacle 138 as clearly depicted in FIGS. 8(a and b).

[0127] In certain embodiments of the present invention, the receptacle is attached to the frame 131 of the payload handling device after the frame is constructed. The process of attaching the receptacle to the frame includes lowering the receptacle into the frame such that the receptacle extends vertically through at least one of the modular sub-frames. The receptacles 138, 338 are shown in FIG. 12d as extending vertically through the third or topmost modular sub-frame 134a of the frame. Also shown in FIG. 12d is that the receptacle 123 is secured to the modular sub-frame by one or more struts 228. The frame is provided with an area for accommodating the receptacle between the first lifting shaft 183a and the second lifting shaft 183b, particularly between the first lifting shaft and the second lifting shaft (see FIG. 9a). To support the receptacle within the frame, the receptacle rests or is mounted on the cross braces 206 that extend across the modular sub-frames of the second modular sections (also known as the intermediate halo) 133a, b, c. In some embodiments, the base of the receptacle is attached to the cross braces 206 of the second modular sections 133a, b, c. The receptacle 138 can be further supported on the frame by securing one or more struts that extend between the receptacle and the frame, particularly up to the modular sub-frames of the second modular sections 133a, b, c. The receptacle provides an unobstructed area within the frame for lowering a power source into the payload handling device (i.e., the battery chute) to engage with the charge receiving element and supply power to the electrical components of the payload handling device. Subsequently, one or more of the electrical components such as the control device and / or the communication module and / or the J-Switch can be attached to the receptacle to draw power from the power source housed within the receptacle.One or more cables are routed from one or more electrical components 144a, 144b, 144c attached to a receptacle to various components for operating a load handling device on a grid structure, such as a drive motor. The attachment of the receptacle to one or more of the electrical components is shown in FIG. 12. Alternatively, one or more electrical components may be attached to the receptacle 138 before attaching the receptacle to a frame.

[0128] Instead of having a separate receptacle that is attached as a separate body to the frame 131 of the load handling device, in an alternative robotic load handling device, as shown in FIGS. 17(a and b), for defining a power supply compartment 238, a receptacle 238 for receiving power may optionally be integrated into the frame 231 of the robotic load handling device. FIG. 17a is a schematic view of an assembly of a modular section by an alternative robotic load handling device, and FIG. 17b is a simplified version of an assembly of a rectangular frame of a modular section depicting a connection block 140. In the particular embodiment shown in FIGS. 17(a and b), an externally accessible open upper end 242 for receiving power is formed substantially vertically, or is formed or integrated into one of a plurality of modular sub-frames of the frame structure 231. Compared to the receptacle 138 shown in FIGS. 9(a and b) where the receptacle extends above the height of the frame 131, in the alternative robotic load handling device, the receptacle forming the power supply compartment 238 may extend partially above the height of the frame 231, or at least be flush with the height of the frame, or be below the height of the frame 231. The assembly of the various modular sections for forming the frame structure 231 of the alternative robotic load handling device is very similar to the assembly of the modular sections described above with reference to FIGS. 8(a and b) and FIGS. 9(a and b) in that the various modular sub-frames 232a, b, 233a, b, 234a, b are arranged as a vertical stack. Compared to the assembly of the modular sub-frames shown in FIGS. 8(a and b) where the receptacle is attached as a separate body to the frame structure, the receptacle 238 in the alternative robotic load handling device is integrated into the frame structure 231 for defining the power supply compartment 238, as shown in FIGS. 18(a and b).When the frame structure is assembled, in contrast to attaching the receptacle as a separate body to the frame structure 231 of the robotic handling device, the advantage of integrating the receptacle into the frame structure is that this eliminates the need to form separate receptacles having a plurality of substantially vertical connecting elements that connect the upper and lower sections of the receptacle, i.e., that connect the open upper end and the base of the receptacle.

[0129] So that the power supply can be received within the frame structure 231 of the robotic payload handling device, the open upper end 242 of the power supply compartment is formed within at least one of the plurality of modular sub - frames 234a, b to which the lifting drive mechanism is attached. As discussed above, the lifting drive mechanism is configured to drive the first lifting shaft 183a and the second lifting shaft 183b. The first lifting shaft 183a and the second lifting shaft 183b are rotatably attached to corresponding connection blocks of the modular sub - frames 234a, b to which the lifting drive mechanism is attached, i.e., the third modular section. Since the first lifting shaft 183a and the second lifting shaft 183b are spaced apart to attach the first set 182a of spools and the second set 182b of spools, respectively, the space between the first lifting shaft 183a and the second lifting shaft 183b defines an externally accessible open upper end 242 for lowering the power supply into the frame structure 231 through this space, as shown in FIGS. 18(a and b). In the particular embodiment shown in FIG. 18a, four corner pieces 244 are attached to the modular sub - frame to which the first lifting shaft 183a and the second lifting shaft 183b are attached to define the externally accessible open upper end 242 of the power supply compartment. The four corner pieces are arranged to provide a substantially rectangular open upper end of the power supply compartment, but in the present invention, other shaped open upper ends, such as circular shapes for receiving a cylindrical power supply, are also applicable, and these upper ends largely depend on the shape of the power supply to be received within the power supply compartment. Each of the four corner pieces 244 has a guide surface for guiding the power supply into the power supply compartment (see FIG. 18a). In the case of a cuboid - shaped power supply, each of the four corner pieces 244 has two vertical guide surfaces for accommodating the corners of the power supply.

[0130] On the one hand, the base 240 of the power supply section 238 for supporting the power supply can be formed within or integrated into the modular sub - frames 233a, b, i.e., the second or intermediate modular sections 233a, b, below the modular sub - frames 234a, b that house the open upper ends 242 (see FIGS. 18a, b). As discussed above, the base 240 of the power supply section 238 can be supported by the cross braces 206 of the intermediate modular sub - frames 233a, b that support at least a part of the wheel positioning mechanism, e.g., a cam mechanism, i.e., in order to form the power supply section 238, the modular sub - frame 234a to which the lifting drive mechanism is attached and the modular sub - frames 233a, b below this modular sub - frame cooperate. The vertical gap between the top third modular sub - frames 234a, b and the second intermediate modular sub - frames 233a, b is such that it accommodates the height of the power supply when the power supply is received within the power supply section. In the specific example shown in FIGS. 18(a and b), the rib - crossing members of the cross braces 206 extend through the base 240 of the power supply section 238. Alternatively, if the height of the connection blocks 140 of the top third modular sub - frames 234a, b is high enough to accommodate the height of the power supply, the base 240 can be supported by the same modular sub - frames 234a, b that house the open upper end of the power supply section, i.e., to which the lifting drive mechanism is attached.

[0131] The assembly of the frame of the robotic payload handling device according to the alternative design shown in FIGS. 17(a and b) and FIGS. 18(a and b) is similar to the assembly of the frame described above with reference to FIGS. 8(a and b) and FIGS. 9(a and b). Here, each of the modular sub-frames 232a, b, 233a, b, 234a, b is assembled together to form a substantially rectangular frame by connecting at least four connection blocks by horizontal connection elements, and the modular sub-frames are arranged as a vertical stack by connecting adjacent modular sub-frames in the vertical direction by vertical continuation elements. In the previous example shown in FIGS. 8(a and b), the receptacle 138 is formed separately by horizontal and vertical continuation elements, whereas in the alternative robotic payload handling device shown in FIGS. 17(a and b), the receptacle 238 is integrated into one or more of the modular sub-frames of the frame structure, eliminating the need for vertical continuation elements forming the receptacle. The vertical continuation elements of the receptacle are provided by the vertical continuation elements that connect adjacent modular sub-frames 232a, b, 233a, b, 234a, b together in the vertical direction. Another advantage of integrating the receptacle into the frame or frame structure of the robotic payload handling device is the elimination of the need to brace the receptacle to the frame by one or more struts 228 due to the receptacle being "buried" within the frame and thus confined within the frame 231. This also enables a more compact robotic payload handling device. Similar to the case of the first example of the robotic payload handling device, the frame 231 forms a three-dimensional structure that defines a volume having an upper portion with a power supply section 238 and a lower portion with a container receiving space 137.

[0132] During operation of the load handling device on the lattice structure, the stress experienced by the open frame structure is concentrated around the joint between the connection block and the connection rod. If the connection rod is not properly fixed to the connection block, one or more of the connection rods may detach from their corresponding connection blocks, resulting in the ultimate failure of the rectangular frame associated with the connection block and, in the worst case, the risk of failure of the open frame structure. To ensure the structural integrity of the resulting open frame structure, the joint for fixing the end of the connection rod to the connection block should have sufficient strength to prevent the end of the connection rod from detaching from the connection block, more specifically from the socket 187 in the connection block. Various joints can be used to fix the end of the connection rod to the connection block, but they depend largely on the materials used in the fabrication of the connection block and the connection rod. The various joints can include, but are not limited to, adhesion or welding, or a combination of any one of these fixing methods.

[0133] During operation of the load handling device on the lattice structure, the energy of the power source is consumed, and in order for the load handling device to continue operating on the lattice structure, it becomes necessary to replace the depleted power source with a replacement power source.

[0134] The power source may be replaced manually, but for convenience and efficiency, and to enable the power source to be replaced while the load handling device remains on the grid structure, it is preferred that a power source replacement device is provided. The power source replacement device can be any suitable "pick and place" robot of any form that can pick up an object and place it in a desired location in a desired manner. Replacing the power source involves exchanging the power source substantially vertically from the receptacle, as shown in Figure 7b. The first or depleted power source is removed from receptacle 138 by lifting the power source vertically from the receptacle. Subsequently, the second or charged power source is lowered vertically into the receptacle so as to engage the charge receiving element of the receptacle. The vertical removal and insertion of the power source do not require any horizontal movement of the load handling device, so the load handling device can remain on the designated grid cell during the power source replacement, including the period of removing the depleted power source, the period of inserting the replacement power source, and the period in between.

Claims

Claim 1 A robotic load handling device for lifting and moving one or more stackable containers in a storage and retrieval system, wherein the storage and retrieval system comprises a lattice structure comprising a plurality of lattice members including a first set of lattice members and a second set of lattice members, and the second set of lattice members is substantially perpendicular to the first set of lattice members such that the plurality of lattice members are arranged in a lattice pattern for guiding the movement of the load handling device on the lattice structure. The load handling device comprises a frame, and the frame a) a container lifting mechanism comprising a container gripping assembly configured to releasably grip a container and a lifting drive mechanism configured to raise and lower the container gripping assembly; b) a first set of wheels for engaging with the first set of lattice members for guiding movement of the load handling device in a first direction, and a second set of wheels for engaging with the second set of lattice members for guiding movement of the load handling device in a second direction, wherein the second direction is transverse to the first direction; c) a wheel positioning mechanism configured to selectively lower or raise the first set of wheels or the second set of wheels to engage or disengage with the first set of lattice members or the second set of lattice members; d) a receptacle for accommodating a power source, wherein the receptacle has an externally accessible open upper end for receiving the power source in a substantially vertical direction and comprises a charging receiving element for electrically coupling with a charge supply element of the power source to supply power to the wheel positioning mechanism and the container lifting mechanism. The frame supports The frame comprises a plurality of modular sub-frames arranged as a vertical stack, and the receptacle extends vertically through at least one of the plurality of modular sub-frames. A robotic load handling device. Claim 2 The robotic load handling device according to claim 1, wherein the frame further supports electrical components including a control device for controlling the container lifting mechanism and the wheel positioning mechanism. Claim 3 The electrical component further includes a communication module for receiving commands from an external central control system, and the control device controls the movement of the load handling device on the grid structure in response to the commands from the communication module. The robotic load handling device according to claim 2.

4. The electrical component is attached to the receptacle. The robotic load handling device according to claim 2 or 3.

5. The receptacle further includes a cable tray attached thereto for wiring one or more electrical cables from the electrical component to the container lifting mechanism and the wheel positioning mechanism. The robotic load handling device according to any one of claims 2 to 4.

6. The robotic load handling device according to any one of claims 2 to 5 further includes one or more cable retaining clips for retaining one or more of the electrical cables in the cable tray.

7. The robotic load handling device according to claim 6, wherein one or more of the cable retaining clips include a plurality of mooring elements configured to engage with the cable tray.

8. Each of the plurality of modular sub-frames of the modular sub-frames includes at least four connection blocks, and each of the at least four connection blocks is connected by one or more horizontal connection elements to two other connection blocks within a single modular sub-frame so as to form a rectangular frame structure. At least four of the connection blocks of adjacent modular sections in the vertical direction can be connected as the vertical stack to form the frame including a plurality of the rectangular frames by one or more substantially vertical connection elements. The robotic load handling device according to any one of claims 1 to 7.

9. The frame is an open frame structure. The robotic load handling device according to claim 8.

10. At least one of the plurality of modular sub-frames is braced by one or more cross-bracing members. The robotic load handling device according to claim 8 or 9.

11. The robotic payload handling device according to claim 10, comprising two cross members, one or more of which are arranged to form a cross brace extending across the at least one rectangular frame structure of the plurality of modular sub-frames.

12. The robotic payload handling device according to claim 11, wherein the receptacle is supported by at least one of the cross braces of the plurality of modular sub-frames.

13. The robotic payload handling device according to any one of claims 1 to 12, wherein the receptacle extends vertically above the height of the frame.

14. The robotic payload handling device according to any one of claims 1 to 13, wherein the charge receiving element is configured to electrically couple to the power source when the power source is received vertically into the receptacle and to electrically decouple from the charge receiving element when the power source is lifted vertically out of the receptacle.

15. The robotic payload handling device according to any one of claims 1 to 14, wherein the receptacle is removably attached to at least one of the plurality of modular sub-frames.

16. The robotic payload handling device according to any one of claims 1 to 15, wherein the receptacle is integrated with at least one of the plurality of modular sub-frames.

17. The robotic payload handling device according to any one of claims 1 to 16, wherein the receptacle is connected to at least one of the plurality of modular sub-frames by at least one support column.

18. The container lifting mechanism comprises i) a first set of spools and a second set of spools, wherein each of the first set of spools and the second set of spools supports a lifting tether having a first end moored to the container gripping assembly and a second end moored to its corresponding spool. ii) a first lifting shaft and a second lifting shaft, wherein the first set of the spools is mounted to rotate on the first lifting shaft, the second set of the spools is mounted to rotate on the second lifting shaft, and the first lifting shaft and the second lifting shaft are connected to the lifting drive mechanism so as to transmit rotation from an output portion of the lifting drive mechanism for raising and lowering the container gripping assembly. comprising The robot-type load handling device according to any one of claims 1 to 17, wherein the first lifting shaft and the second lifting shaft are spaced apart such that the receptacle is disposed between the first lifting shaft and the second lifting shaft.

19. The robot-type load handling device according to claim 18, wherein the lifting drive mechanism includes a drive pulley and a plurality of timing pulleys connected by an endless belt so as to rotate together with the first set of the spools and the second set of the spools.

20. The robot-type load handling device according to claim 18 or 19, wherein the first lifting shaft and the second lifting shaft are mounted to rotate on at least one of the plurality of modular sub-frames surrounding the receptacle.

21. The robot-type load handling device according to any one of claims 1 to 20, wherein the receptacle includes a base and an upwardly rising side wall extending from the base.

22. The robot-type load handling device according to any one of claims 1 to 21, wherein the receptacle includes a plurality of connection blocks connected by a plurality of connection elements so as to define an open frame structure.

23. The robot-type load handling device according to any one of claims 1 to 22, wherein the receptacle includes at least eight connection blocks, and each of the at least eight connection blocks is connected to two other connection blocks in a horizontal plane by one or more horizontal connection elements and to one other connection block in a vertical plane by one or more vertical connection elements so as to form a rectangular parallelepiped frame structure.

24. The frame defines a volume having an upper portion and a lower portion, the upper portion comprising the receptacle and the lower portion comprising a container receiving space, the robotic load handling device according to any one of claims 1 to 23.

25. The robotic load handling device according to any one of claims 1 to 24, wherein one or more of the plurality of modular sub-frames comprise at least a part of the container lifting mechanism and / or the wheel assembly and / or the wheel positioning mechanism.

26. The robotic load handling device according to claim 24, wherein at least a part of the container lifting mechanism and / or the wheel assembly and / or the wheel positioning mechanism is integrated into one or more of the plurality of modular sub-frames.

27. The robotic load handling device according to claim 25 or 26, wherein any one of the container lifting mechanism and / or the wheel assembly and / or the wheel positioning mechanism is shared between two or more of the plurality of modular sub-frames.

28. A method of constructing a robotic load handling device comprising a frame, the frame comprising a) a container lifting mechanism comprising a container gripping assembly configured to releasably grip a container and a lifting drive mechanism configured to raise and lower the container gripping assembly; b) a first set of wheels for engaging a first set of grid members for guiding movement of the load handling device in a first direction and a second set of wheels for engaging a second set of grid members for guiding movement of the load handling device in a second direction, wherein the second direction is substantially perpendicular to the first direction; c) a wheel positioning mechanism configured to selectively lower or raise the first set of wheels or the second set of wheels to engage or disengage with the first set of grid members or the second set of grid members; d) a charge receiving element for electrically coupling to a charge supply element of a rechargeable power source to supply power to the wheel positioning mechanism and the container lifting mechanism; supporting The method comprising the following steps, namely i) forming a plurality of modular sub-frames, each of the plurality of modular sub-frames being formed by connecting at least four connection blocks together by one or more horizontal connection elements; ii) connecting the connection blocks of adjacent modular sub-frames in the vertical direction by one or more vertical continuation elements to connect the plurality of modular sub-frames together as a vertical stack to form the frame; iii) attaching a receptacle for accommodating a power source to the frame such that the receptacle extends vertically through at least one of the plurality of modular sub-frames, wherein the receptacle comprises a charge receiving element for electrically coupling to a charge supply element of the power source and an externally accessible open upper end for receiving the power source substantially vertically; A method comprising the above.

29. The method according to claim 28, further comprising attaching the receptacle to at least one of the plurality of modular sub-frames.

30. The method according to claim 28 or 29, further comprising bracing the receptacle to the frame by one or more cross-bracing members or struts.

31. The method according to any one of claims 28 to 30, wherein each of the modular sub-frames is formed by inserting one or more of the plurality of horizontal connection elements into one or more openings of one or more of the at least four connection blocks.

32. The method according to claim 31, wherein the plurality of modular sub-frames are connected together as the vertical stack by inserting one or more vertical continuation elements into one or more openings in one or more of the at least four connection blocks of adjacent modular sub-frames in the vertical direction.

33. The method according to any one of claims 28 to 32, further comprising integrally forming at least a part of the container lifting mechanism, and / or the wheel assembly, and / or the wheel positioning mechanism, from one or more of the at least four connection blocks of one or more of the plurality of modular sub-frames.

34. The method according to any one of claims 28 to 33, further comprising the step of additive manufacturing or 3D printing one or more of at least four of the connection blocks of one or more of the plurality of modular sub-frames.

35. A method for replacing a power source within a receptacle of a robotic load handling device according to any one of claims 1 to 27, the method comprising the following steps, namely (i) removing a first power source vertically from the receptacle; and (ii) inserting a second power source vertically into the receptacle.

36. The method according to claim 35, wherein the robotic load handling device remains stationary at least in the horizontal direction from when the first power source is removed until when the second power source is inserted.

37. A robotic load handling device for lifting and moving one or more stackable containers in a storage and retrieval system, the storage and retrieval system comprising a lattice structure comprising a plurality of lattice members including a first set of lattice members and a second set of lattice members, the second set of lattice members being substantially perpendicular to the first set of lattice members such that the plurality of lattice members are arranged in a lattice pattern for guiding the movement of the load handling device on the lattice structure, the load handling device comprises a frame, the frame comprising a) a container lifting mechanism comprising a container gripping assembly configured to releasably grip a container and a lifting drive mechanism configured to raise and lower the container gripping assembly; and b) a first set of wheels for engaging a first set of the lattice members for guiding movement of the load handling device in a first direction, and a second set of wheels for engaging a second set of the lattice members for guiding movement of the load handling device in a second direction, wherein the second direction is substantially transverse to the first direction; and c) a wheel positioning mechanism configured to selectively lower or raise the first set of wheels or the second set of wheels to engage or disengage with the first set of the lattice members or the second set of the lattice members. d) a power compartment having an externally accessible open upper end for receiving the power substantially in a vertical direction and a base for supporting the power, wherein the power compartment comprises a charge receiving element for electrically coupling to a charge supply element of the power to supply power to the wheel positioning mechanism and the container lifting mechanism, comprising, The frame comprises a plurality of modular sub-frames arranged as a vertical stack, the lifting drive mechanism is attached to at least one of the plurality of modular sub-frames, and the externally accessible open upper end of the power compartment is formed within at least one of the plurality of modular sub-frames to which the lifting drive mechanism is attached. A robotic load handling device.

38. The container lifting mechanism, i) a first set of spools and a second set of spools, wherein each of the first set of spools and the second set of spools supports a lifting tether having a first end moored to the container gripping assembly and a second end moored to its corresponding spool, ii) a first lifting shaft and a second lifting shaft, wherein the first set of spools is rotatably mounted on the first lifting shaft and the second set of spools is rotatably mounted on the second lifting shaft, and the first lifting shaft and the second lifting shaft are connected to the lifting drive mechanism to transmit rotation from an output of the lifting drive mechanism to raise and lower the container gripping assembly. comprising, The robotic load handling device according to claim 37, wherein the first lifting shaft and the second lifting shaft are spaced apart such that the externally accessible open upper end of the power compartment is disposed between the first lifting shaft and the second lifting shaft.

39. Each of the plurality of modular sub - frames includes at least four connection blocks, and each of the at least four connection blocks is connected by one or more horizontal connection elements to two other connection blocks within a single modular sub - frame so as to form a rectangular frame structure. At least four of the connection blocks of adjacent modular sections in the vertical direction can be connected as the vertical stack so as to form the frame including a plurality of the rectangular frames by one or more substantially vertical connection elements. The robotic payload handling device according to claim 38.

40. The first lifting shaft and the second lifting shaft are rotatably attached to at least four modular connection blocks of at least one of the plurality of modular sub - frames to which the lifting drive mechanism is attached. The robotic payload handling device according to claim 39.

41. The externally accessible open upper end of the power supply section is formed by four corner pieces attached to at least one of the plurality of modular sub - frames to which the lifting drive mechanism is attached. The robotic payload handling device according to any one of claims 37 - 40.

42. The base is attached to at least one of the plurality of modular sub - frames to which the lifting drive mechanism is attached. The robotic payload handling device according to any one of claims 37 - 41.

43. The base is attached to at least one of the plurality of modular sub - frames positioned below at least one of the plurality of modular sub - frames to which the lifting drive mechanism is attached. The robotic payload handling device according to any one of claims 37 - 41.

44. The base is attached to at least one of the plurality of modular sub - frames via cross braces. The robotic payload handling device according to claim 42 or 43.

45. The robot type load handling device according to any one of claims 37 to 44, wherein the frame defines a volume having an upper portion and a lower portion, the upper portion includes the power supply compartment, and the lower portion includes a container receiving space.

46. An automated storage and retrieval system comprising: a lattice structure including a plurality of lattice members including a first set of lattice members and a second set of lattice members, wherein the second set of lattice members is substantially perpendicular to the first set of lattice members such that the plurality of lattice members are arranged in a lattice pattern for guiding the movement of one or more load handling devices operating on the lattice structure; at least one of the robot type load handling devices according to any one of claims 1 to 45.

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