Storage and collection system

Abstract

A power bank for charging a load handling device, comprising an auxiliary rechargeable power source and at least one power transfer means electrically coupled to the auxiliary rechargeable power source, wherein the at least one power transfer means is configured to be electrically coupled to the load handling device for transferring power from the auxiliary rechargeable power source to the load handling device, and a power bank is provided.

Description

Technical Field

[0001] The present invention relates to the field of storage and retrieval systems, and more particularly to a load handling device operable on a track system having a grid framework structure, and more particularly to charging the power supply of the load handling device. The grid framework structure comprises a support framework structure on which a track system is mounted that supports a remotely operated load handling device for handling storage containers stacked within the grid framework structure.

Background Art

[0002] The claimed invention is intended to provide an improvement in charging the power supply of a load handling device operating in an automated storage and retrieval system.

[0003] Load handling devices are typically powered by a rechargeable power source. The rechargeable power source needs to be recharged when depleted in order to allow the load handling device to continue operating. Charging can take a significant amount of time and may reduce the useful operating time of the load handling device.

[0004] The charging time of a rechargeable power source can represent a long downtime while the load handling device remains inactive or inoperable. If some load handling devices are operable in an automated storage and retrieval system to fulfill customer orders within a given time slot, leaving one or more load handling devices idle for a long time can negatively impact the ability of a fulfillment center or logistics warehouse to fulfill orders in a timely manner. This is particularly true when the load handling device contributes to a logistics system that provides home delivery of goods to a customer's facility upon receipt of an order. Here, delivery information including the delivery address is used by online retailers such as Amazon and Ocado in the UK to deliver goods to the customer's delivery address. To mitigate such problems, online retailers such as Ocado in the UK provide a buffer zone for load handling devices operable on a track system with a grid framework structure to address load handling devices that remain idle during charging. In extreme cases, the time slot for order delivery is extended to address this downtime.

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

[0006] Typically, a charging station is provided above the track system at the edge of a grid framework structure. The charging station allows the load handling device to be charged without leaving the track system but has the drawback of occupying a large amount of space that could otherwise be used for storing goods.

[0007] Therefore, there is a need for a storage and retrieval system that does not occupy a large amount of space that could otherwise be used for storing goods and allows the load handling device to be quickly and easily charged without having a long downtime. SUMMARY OF THE INVENTION

[0008] A power bank for charging a load handling device, the power bank comprising: an auxiliary rechargeable power source; at least one power transfer means electrically coupled to the auxiliary rechargeable power source; A power bank is provided, wherein at least one power transfer means is configured to be electrically coupled to the load handling device to transfer power from the auxiliary rechargeable power source to the load handling device.

[0009] In another aspect, a load handling device comprising: 1) a main rechargeable power source; 2) a container receiving space configured to receive a power bank as defined herein; 3) a container engaging assembly configured to engage the power bank and a container lifting device comprising a drive mechanism configured to lift the power bank into the container receiving space; A load handling device is provided, wherein the load handling device is configured to receive power from the power bank when the power bank is received within the container receiving space of the load handling device.

[0010] As used herein, the terms "container lifting means" and "container lifting device" are used interchangeably.

[0011] The container receiving space may comprise a charging receiving element for receiving power from the power bank to charge the main rechargeable power source.

[0012] The container engaging assembly may comprise one or more grippers, and the outer casing may be configured to be gripped by the grippers. The outer casing may be gripped, clamped, or held by the grippers.

[0013] In another aspect, a storage and retrieval system comprising: A) a grid framework structure, the grid framework structure being i) A track system comprising a plurality of tracks arranged in a grid pattern; ii) A support framework structure for supporting the track system; iii) A plurality of stacks of storage containers arranged in a plurality of storage columns located below the track system. B) A load handling device as defined herein, wherein the container receiving space is further configured to receive a storage container, the container engagement assembly is further configured to engage the storage container, and the drive mechanism is further configured to lift the storage container from a stack of the plurality of stacks into the container receiving space. Comprising A storage and recovery system is provided, wherein one or more of the storage containers in the stack is a power bank as defined herein.

[0014] In another aspect, a storage and recovery system A) A grid framework structure, the grid framework structure comprising i) A track system comprising a plurality of tracks arranged in a grid pattern; ii) A support framework structure for supporting the track system; iii) A plurality of stacks of storage containers arranged in a plurality of storage columns located below the track system. B) A load handling device, the load handling device comprising 1) A main rechargeable power source; 2) A charging receiving element for receiving power to charge the main rechargeable power source, a container receiving space for receiving a storage container; 3) A container lifting means comprising a container engagement assembly configured to engage the storage container and a drive mechanism for lifting the storage container from a stack of the plurality of stacks into the container receiving space. Comprising One or more of the storage containers within the stack are power banks, and the power bank is an auxiliary rechargeable power source, and at least one power transfer means electrically coupled to the auxiliary rechargeable power source within the power bank, and the at least one power transfer means is configured to electrically couple to a charge receiving element of the load handling device to transfer power from the auxiliary rechargeable power source within the power bank to the main rechargeable power source within the load handling device when the power bank is received within the container receiving space of the load handling device. A storage and recovery system is provided that includes

[0015] The advantage of providing a power bank that can charge a load handling device is that no separate charging station is required, thus saving space within the storage system. Charging stations are typically positioned at the edge of the track system and occupy a lot of space, not only the space above the track system but also the storage columns below the charging station, which cannot be used to store items or products. The number and location of the power banks can be selected to suit the charging requirements of the load handling device as well as the processing capacity of the storage and recovery system.

[0016] The at least one power transfer means may comprise at least one electrical coupling element, and the at least one electrical coupling element comprises a primary charge providing element configured to electrically couple the power bank to a charge receiving element on the load handling device to charge the main rechargeable power source within the load handling device.

[0017] The primary charging provision element on the power bank may comprise a primary charging provision contact, and the charging acceptance element on the load handling device may comprise a charging acceptance contact, whereby power is transmitted by contact between the primary charging provision contact and the charging acceptance contact. Alternatively, the primary charging provision element on the power bank may comprise a wireless charging transmitter, and the primary charging acceptance element on the load handling device may comprise a wireless charging receiver, whereby power is wirelessly transmitted from the wireless charging transmitter to the wireless charging receiver. Power transmission by contact has the advantage of being simple, while wireless power transmission has the advantage of no wear on the charging provision element on the power bank and the primary charging acceptance element on the load handling device as it does not require contact.

[0018] The power bank may comprise an outer casing configured to be received within the container receiving space of the load handling device, and the outer casing may comprise one or more engagement features configured to engage with a container engagement assembly. The engagement features may comprise one or more openings within the upper side surface of the outer casing of the power bank, and the openings are configured to be engaged by the container engagement assembly of the load handling device. The container engagement assembly may comprise one or more grippers, and the outer casing may be configured to be clamped or grasped by the grippers. The outer casing may comprise one or more rims or lips, and the container engagement assembly may be configured to catch under the rim or lip. The outer casing may have the same dimensions or substantially the same dimensions as the storage container.

[0019] The advantage of the features described in the above section is that the load handling device can engage with the power bank in the same way as a standard storage container. No changes to the container engagement assembly are required to lift the power bank into the container receiving space and enable its use to charge the load handling device. The only change required to the load handling device is to add a charge receiving element to electrically couple with the power bank and receive charging therefrom. Thus, existing storage and retrieval systems can be easily retrofitted to operate with the power bank instead of an external charging station.

[0020] The outer casing may comprise a base, side walls, and an opening for receiving an auxiliary rechargeable power source. The auxiliary rechargeable power source within the power bank may be one or more supercapacitors, or an assembly of supercapacitors. The advantage of using supercapacitors as the auxiliary power source is the speed of charging. By being able to quickly charge the load handling device, the required downtime is reduced and the processing capacity of the storage and retrieval system is increased. By using multiple supercapacitors, a higher power density and a higher energy storage capacity are achieved.

[0021] The assembly of supercapacitors may comprise a string of supercapacitor elements connected in series, where each element of the string comprises a plurality of supercapacitors connected in parallel. A particular arrangement of supercapacitor elements connected in parallel to form supercapacitor elements connected in series is particularly advantageous. By connecting the supercapacitors in parallel, it becomes possible to more easily monitor the voltage of the supercapacitors to ensure that they do not operate at a voltage higher than the rated voltage, which could damage the supercapacitors. By connecting the supercapacitors in series, the voltage increases.

[0022] Alternatively, the rechargeable power source within the power bank may be a rechargeable battery. Since rechargeable batteries have the advantage of energy density, the power bank can provide more charges to the load handling device.

[0023] The power bank may further include a voltage converter for converting the voltage from an auxiliary rechargeable power source within the power bank to charge the main rechargeable power source within the load handling device. The voltage converter may be a DC-DC converter, such as a boost converter. The boost converter enables a larger proportion of the operating range of the auxiliary rechargeable power source to be used. This is particularly relevant in the specific case where the auxiliary rechargeable power source within the power bank is a supercapacitor and the main rechargeable power source within the load handling device is a battery, due to the non-linear shape of the battery charging curve. Without a DC-DC converter, when the supercapacitor voltage drops below the battery voltage, charging of the battery stops.

[0024] One or more of the storage columns may comprise a charging surface, the charging surface comprising charging provision elements for charging the power bank when the charging surface is electrically coupled to the power bank. The charging surface is a base charging plate, whereby the power bank electrically couples to the base charging plate when mounted thereon. The use of the base charging plate has the advantage of being easily retrofitted to existing storage and retrieval systems. Since the base charging plate is at the base of the storage column, no changes to the structure of the storage column or grid framework structure are required. Indeed, the base charging plate still enables the storage column to be used as a standard storage column for storing storage containers and charging power banks. Flexibility in charging can be achieved by fitting more storage columns with base charging plates, so that the storage columns can be used for either charging or storage, depending on the requirements of the system at a given time. For example, during busy times when many orders are being fulfilled, the storage column provided with the base charging plate can be used for storing storage containers for merchandise or items picked for customer orders, thus increasing storage density and throughput, while during less busy times, the same storage column can be used to charge power banks.

[0025] Alternatively, the charging surface may be a bus bar extending upwardly along the storage column, whereby the bus bar electrically couples to the side of the power bank. This arrangement has the advantage that any power bank in a stack of power banks can be charged directly from the bus bar. The power bank at the top of the stack of power banks can thus be charged directly from the bus bar, while in the example where the charging surface is a base charging plate, the top power bank is charged by the lower power banks in the stack (as will be described later), so that charging proceeds upwardly from the base charging plate through each power bank in the stack of power banks to the top power bank.

[0026] At least one electrical coupling element of the power bank may further comprise a primary charge receiving element configured to receive power from a charge providing element of the charging surface. The charge receiving element is electrically coupled to an auxiliary power source within the power bank and can thus charge an auxiliary rechargeable power source.

[0027] At least one electrical coupling element of the power bank may further comprise a secondary charge providing element for electrically coupling to a vertically adjacent power bank above in the stack and a secondary charge receiving element for electrically coupling to a vertically adjacent power bank below in the stack, such that when disposed within a stack of power banks, power can be transmitted from one power bank to another within the stack.

[0028] The storage and recovery system may comprise a plurality of power banks disposed within a stack, wherein each of its secondary charge providing elements and secondary charge receiving elements are electrically coupled to each other within the stack to transmit charge from a lower power bank in the stack to a higher power bank in the stack. This arrangement has the advantage of enabling the upward transmission of charge through the stack to charge power banks that are not directly electrically coupled to the charging surface. Thus, in the example where the charging surface is a base charging plate, the base charging plate can provide power to charge not only a single power bank attached to the top of the base charging plate but also the entire stack of power banks.

[0029] The secondary charge providing element and the secondary charge receiving element may each comprise a secondary charge providing contact and a secondary charge receiving contact. Alternatively, the secondary charge providing element and the secondary charge receiving element may each comprise a wireless charging transmitter and a wireless charging receiver. Power transmission by contact has the advantage of being simple, while wireless power transmission has the advantage of not requiring contact and thus no wear on the charge providing element on the power bank and the primary charge receiving element on the load handling device.

[0030] In another aspect, the present invention is a method for transmitting power to a load handling device operable within a storage and retrieval system as defined herein, the method comprising: a) moving the load handling device on a track system to a location above a stack comprising a power bank; and b) using container lifting means to lift the power bank into a container receiving space of the load handling device such that at least one power transmission means is electrically coupled to a charge receiving element of the load handling device so that power is transmitted from an auxiliary power source within the power bank to a main rechargeable power source of the load handling device. A method is provided that further comprises.

[0031] In another aspect, the present invention is a method for transmitting power to a load handling device operable within a storage and retrieval system as defined herein, wherein the storage and retrieval system comprises a first load handling device and a second load handling device, the method comprising: a) moving a first load handling device on a track system to a location above a stack comprising a power bank; b) using container lifting means to lift the power bank into a container receiving space of the first load handling device; c) moving the first load handling device on the track system to a predetermined location; d) returning the power bank from the first load handling device to a stack below a target location within a grid framework structure; and e) lifting the power bank into a container receiving space of a second load handling device such that power is transmitted from an auxiliary power source within the power bank to a main rechargeable power source of the second load handling device. A method is provided that comprises.

[0032] The predetermined location can be a grid cell adjacent to or in the vicinity of the second load handling device. Advantageously, the method enables the second load handling device to be recharged without having to travel to a power bank or charging station that is remotely located in a different part of the truck structure, for example. For example, if the main power source of the second load handling device is partially depleted and has only enough charge to move a short distance, the second load handling device can retrieve and recharge a power bank from a predetermined location rather than becoming immobile on the truck system because it cannot travel to another power bank or charging station.

[0033] The above method may further comprise the step of the load handling device returning the power bank to a stack within the grid framework structure. The above method may further comprise the step of the power bank being recharged within the stack of the grid framework structure.

[0034] Further features and aspects of the present invention will become apparent from the following detailed description of exemplary embodiments made with reference to the figures.

Brief Description of the Drawings

[0035]

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DETAILED DESCRIPTION OF THE INVENTION

[0036] The following embodiments represent examples preferred by the applicant of the method of implementing the present invention, but these are not necessarily the only examples of the ways in which they can be achieved. Grid framework structure Figure 1 shows a grid framework structure 1 comprising a support framework structure 2 that supports a track structure 13. The support framework structure 2 can take any suitable form. In the particular example shown in Figure 1, the support framework structure 2 comprises a plurality of upright members 3 and horizontal members 5, 7 supported by the upright members 3. The upright members 3 may also be referred to as upright columns 3. The horizontal members 5 extend parallel to each other and to the illustrated x-axis. The horizontal members 7 extend parallel to each other and to the illustrated y-axis, in a direction transverse to the horizontal members 5. The upright members 3 extend parallel to each other and to the illustrated z-axis, in a direction transverse to the horizontal members 5, 7. The horizontal members 5, 7 form a grid pattern that defines a plurality of grid cells. In the example shown, storage containers 9 are arranged in stacks 11, one stack 11 of storage containers 9 per grid cell, below the grid cells defined by the grid pattern.

[0037] Figure 2 shows an enlarged plan view of a section of the track structure 13 that forms part of the grid framework structure 1 illustrated in Figure 1 and is located above the horizontal members 5, 7 of the grid framework structure 1 illustrated in Figure 1. The track structure 13 may be provided by the horizontal members 5, 7 themselves (e.g., formed within or on the surface of the horizontal members 5, 7), or by one or more additional components attached to the upper part of the horizontal members 5, 7. The illustrated track structure 13 comprises an x-direction track 17 and a y-direction track 19, i.e., a first set of tracks 17 extending in the x-direction and a second set of tracks 19 extending in the y-direction, which is transverse to the tracks 17 within the first set of tracks 17. The tracks 17, 19 define an opening 15 at the center of the grid cell. The opening 15 is sized to enable the storage container 9 located below the grid cell to be lifted and lowered through the opening 15. The x-direction tracks 17 are provided in pairs separated by a channel 21, and the y-direction tracks 19 are provided in pairs separated by a channel 23. Other arrangements of the track structure may also be possible.

[0038] As an alternative to the support framework structure 2 described with reference to FIG. 1, in other examples, the support framework structure comprises a plurality of pre-assembled modular panels arranged in a grid pattern that is briefly described below and fully detailed in WO2022034195A1 of a PCT application incorporated herein by reference under the name of Ocado Innovation Ltd. This grid framework structure 1 described in WO2022034195A1 provides a support grid framework structure 2 comprising a plurality of pre-assembled modular panels arranged in a three-dimensional grid pattern to define a plurality of grid cells, thereby addressing the issues of assembly time and cost. Each of the grid cells of the support framework structure 2 is sized to support two or more grid cells of the track system 13. The grid framework structure 1 is formed from fewer structural components while still maintaining the same structural integrity as the typical "stick-built" grid framework structure 1 described above, and is much faster and cheaper to construct.

[0039] Any suitable support framework structure 2 may be used in the present invention. Load handling device FIG. 3 shows a plurality of load handling devices 31 moving above the grid framework structure 1 illustrated in FIG. 1. The load handling device 31, which may also be referred to as a robot 31 or a bot 31, is provided with a set of wheels for engaging with the corresponding x-direction track 17 or y-direction track 19 to enable the load handling device 31 to travel across the track structure 13 and reach a particular grid cell. The illustrated pair of tracks 17, 19 separated by the channels 21, 23 enables the load handling devices 31 to occupy (or pass by each other) adjacent grid cells without colliding with each other.

[0040] As shown in detail in FIG. 4, the load handling device 31 includes a main body 33 with one or more components mounted therein or thereon that enable the load handling device 31 to perform its intended functions. These functions may include moving across the grid framework structure 1 on the track structure 13 and raising or lowering the container 9 (from or to the stack 11) so that the load handling device 31 can retrieve or deposit the container 9 at specific locations defined by the grid pattern.

[0041] The load handling device 31 includes a wheel assembly 34. The illustrated embodiment of the load handling device 31 in FIG. 4 includes first and second sets of wheels 35, 37 that are mounted on the main body 33 of the load handling device 31 and that enable the load handling device 31 to move in the x - and y - directions along tracks 17 and 19, respectively. In particular, two wheels 35 are provided on the shorter side surface of the load handling device 31 visible in FIG. 4, and another two wheels 35 are provided on the shorter side surface on the opposite side of the load handling device 31 (the side surface and the other two wheels 35 are not visible in FIG. 4). The wheels 35 engage the track 17 and are rotatably mounted on the main body 33 of the load handling device 31 to enable the load handling device 31 to move along the track 17. Similarly, two wheels 37 are provided on the longer side surface of the bot 31 visible in FIG. 4, and another two wheels 37 are provided on the longer side surface on the opposite side of the load handling device 31 (the side surface and the other two wheels 37 are not visible in FIG. 4). The wheels 37 engage the track 19 and are rotatably mounted on the main body 33 of the load handling device 31 to enable the load handling device 31 to move along the track 19.

[0042] The wheel assembly 34 of the load handling device 31 may be driven by a drive mechanism 38. The drive mechanism 38 may include one or more motors.

[0043] The load handling device 31 also includes container lifting means 39 configured to raise and lower the storage container 9. The illustrated container lifting means 39 includes four tapes or reels 41 having lower ends connected to a container engagement assembly 43. The container engagement assembly 43 includes engagement means configured to engage features of the storage container 9 (e.g., may be provided at the corners of the assembly 43 near the tapes 41). For example, the storage container 9 may be provided with one or more openings in its upper side surface into which the engagement means can engage. Alternatively or additionally, the engagement means may be configured to catch under the rim or lip of the storage container 9 and / or may clamp or grip the storage container 9. The tapes 41 may be wound or unwound as necessary to raise or lower the container engagement assembly. The container lifting means 39 may be driven by a drive mechanism 38. The winding or unwinding of the tapes 41 of the container lifting means 39 may be effected or controlled by a drive mechanism 38 that may include one or more motors or other means. The same drive mechanism 38 can be used to drive both the wheel assembly 34 and the container lifting means 39, or separate drive means may be used to drive the wheel assembly and to drive the container lifting means.

[0044] As can be seen in FIG. 5, the body 33 of the illustrated load handling device 31 has an upper portion 45 and a lower portion 47. The upper portion 45 is configured to accommodate one or more operating components (not shown). The lower portion 47 is disposed below the upper portion 45. The lower portion 47 includes a container receiving space 49 or cavity for receiving at least a portion of the storage container 9 lifted by the container lifting means 39. The container receiving space 49 is sized such that the storage container 9 can fit sufficiently inside the cavity to allow the load handling device 31 to move across the track structure 13 at the upper part of the grid framework structure 1 without the lower surface of the storage container 9 being caught by the track structure 13 or another part of the grid framework structure 1. When the load handling device 31 reaches its intended destination, the container lifting means 39 controls the tape 41 to lower the container engagement assembly 43 and the corresponding storage container 9 from the container receiving space 49 in the lower portion 47 and place it in the intended position. The intended position may be a stack 11 of storage containers 9 or an exit point of the grid framework structure 1 (or an entry point of the grid framework structure 1 if the load handling device 31 has moved to collect a container 9 for the grid framework within the grid framework structure 1). In the illustrated example, the upper portion 45 and the lower portion 47 are separated by a physical dividing plate, but in other embodiments, the upper portion 45 and the lower portion 47 may not be physically separated by a specific component or part of the body 33 of the load handling device 31.

[0045] In some embodiments, the container receiving space 49 of the load handling device 31 may not be within the body 33 of the bot 31. For example, in some embodiments, the container receiving space 49 may be adjacent to the body 33 of the load handling device 31. For example, the weight of the body 33 of the load handling device 31 may be in a cantilever arrangement balanced with the weight of the container to be lifted. In such embodiments, the frame or arm of the container lifting means 39 may project horizontally from the body 33 of the load handling device 31, the tape / reel 41 may be disposed at respective locations on the projecting frame / arm, and may be configured to be raised and lowered from these locations to raise and lower the container within the container receiving space 49 adjacent to the body 33. The height at which the frame / arm is mounted on and projects from the body 33 of the load handling device 31 may be selected to provide the desired effect. For example, it may be preferable for the frame / arm to project at a high height on the body 33 of the load handling device 31 to enable a larger container (or containers) to be raised into the container receiving space below the frame / arm. Alternatively, the frame / arm may be arranged to project downwardly along the body 33 (but still at a height sufficient to accommodate at least one container between the frame / arm and the track structure 13) to keep the center of mass of the load handling device 31 downward when a container is loaded onto the load handling device 31.

[0046] A particular example of the load handling device illustrated in FIGS. 4 and 5 shows a load handling device 31 having a body 33 that is substantially box-shaped with four side walls and an upper wall, and with the components of the load handling device 31 being housed within the body 33. In other examples, the body 33 may comprise an open frame or skeleton structure on or within which the components of the load handling device 31 are supported.

[0047] To enable the load handling device 31 to move in the first and second directions on different wheels 35, 37, the load handling device 31 includes a wheel positioning mechanism for selectively engaging either the first set of wheels 35 with the first set of tracks 17 of the grid framework structure 1 or the second set of wheels 37 with the second set of tracks 19. The wheel positioning mechanism is configured to raise and lower the first set of wheels 35 and / or the second set of wheels 37 relative to the body 33, thereby enabling the load handling device 31 to selectively move in either the first or second direction across the tracks 17, 19 of the grid framework structure 1.

[0048] The wheel positioning mechanism may include one or more liner actuators, rotary components, or other means for raising and lowering at least one set of the wheels 35, 37 relative to the body 33 of the load handling device 31 to remove and contact at least one set of the wheels 35, 37 from the tracks 17, 19. In some examples, only one set of wheels is configured to be raised and lowered, and the action of lowering one set of wheels may effectively lift the other set of wheels away from the corresponding track, while the action of raising one set of wheels may effectively lower the other set of wheels to contact the corresponding track. In other examples, both sets of wheels may be raised and lowered, which advantageously means that the body 33 of the load handling device 31 remains at substantially the same height, and thus there is no need to lift and lower the weight of the body 33 and the components attached thereto by the wheel positioning mechanism.

[0049] The drive mechanism 38 used to drive the wheel assembly 34 and the container lifting means 39 may be powered by a main rechargeable power source 53.

[0050] In some examples, the grid framework structure 1 may include one or more port columns or vertical shoots to facilitate inserting or removing a storage container into or from the grid framework structure. The port column occupies one grid cell 14 joined at four corners by four of the vertical uprights 3 of the grid framework structure 1. Vertical guides may be provided to guide the storage container 9 vertically. To remove the storage container 9 from the grid framework structure 1, the load handling device 31 transporting the storage container 9 in the container receiving space 49 travels to the grid cell 14 at the top of the port column and lowers the storage container 9 downward until the storage container 9 reaches the bottom of the port column. The container engagement assembly 43 of the load handling device 31 then disengages from the storage container 9, is lifted, and is returned into the body 33 of the load handling device. The storage container 9 at the bottom of the port column can then be removed, for example, by a conveyor belt or a vehicle or by manual operation.

[0051] To bring the storage container 9 into the grid framework structure 1, the same operations are used in reverse. The storage container 9 is brought to the bottom of the port column (e.g., by a conveyor belt or a vehicle or by manual operation). The load handling device 31 travels to the grid cell at the top of the port column and lowers its container engagement assembly 43 along the port column. The container engagement assembly engages the storage container, and the container lifting means 39 lifts the storage container 9 upward through the port column and into the container receiving space 49 of the load handling device 31. The load handling device then travels along the track structure to transport the storage container to its intended location within the grid framework structure. Container lifting means FIG. 6 shows a container lifting means 39 known in the art, comprising a container engagement assembly 43, known as a grabber device, for releasably connecting to a lower storage container 9, and a drive mechanism 38 for raising and lowering the container engagement assembly 43. The drive mechanism 38 can be the same drive mechanism used to drive both the wheel assembly 34 and the container lifting means 39, or a separate drive mechanism may be used.

[0052] To raise and lower the container engagement assembly 43, a drive mechanism 38 known in the art comprises a set of lifting tapes or bands 41 extending vertically between the container engagement assembly 43 and the drive mechanism 38. For maximum stability and load capacity, generally four lifting tapes 41 wound on separate spools 82 are shown extending between the drive mechanism 38 and each corner of the container engagement assembly 43. In an exemplary embodiment of the present invention, the container engagement assembly 43 is formed as a frame having four corner sections and an upper side 88 and a bottom side 90 (see FIG. 7). To grip the container 9, the container engagement assembly 43 includes four positioning pins or guide pins 80 near or at each corner of the container engagement assembly 43 that mate with corresponding notches or holes (not shown) formed at the four corners of the container 9. Four gripper elements 84 are disposed on the bottom side of the container engagement assembly 43 for engaging the rim of the container 9 (see FIGS. 7 and 8). The positioning pins 80 serve to properly align the gripper elements 84 with corresponding holes or openings in the rim of the container 9. In the particular embodiment shown in FIG. It has a pair of wings that can be folded so as to be receivable within corresponding holes or openings 86 (see FIG. 6) within the rim of the container 9, and an open or expanded configuration having a size larger than the holes 86 (see FIG. 6) within the rim of the container 9 in at least one dimension for locking onto the container. The wings are actuated to open and closed configurations by a suitable actuation mechanism coupled to a drive gear, although other actuation mechanisms for actuating gripper elements known in the art are applicable to the present invention. In the particular example shown in FIG. 7, at least one head of the wing comprises a plurality of teeth meshing with the drive gear such that when the gripper element 84 is actuated by the actuation mechanism, the rotation of the drive gear rotates the pair of wings from a closed or folded configuration to an open and expanded configuration (FIGS. 7 and 8).When folded or in the closed configuration, the gripper element 84 is sized to be receivable within a corresponding hole 86 within the rim of the container 9 as shown in FIG. 6. Each leg of the pair of wings is provided with a stopper 89, such as a boss, whereby when received within a corresponding hole 86 within the rim of the container 9, the stopper 89 engages the lower surface of the rim when in the expanded open configuration to lock the container when the container engagement assembly 43 is wound upwardly towards the container receiving space 49 of the load handling device 31. Power bank The present invention provides a power bank 51 configured to charge the load handling device 31. The power bank 51 includes an outer casing 57 configured to be received within the container receiving space 49 of the load handling device 31, and an auxiliary rechargeable power source 55 housed within the outer casing 57. One or more auxiliary rechargeable power sources 55 may be provided within the same power bank 51. The outer casing 57 includes one or more engagement features. The engagement features of the power bank 51 are configured to engage with the engagement means of the container engagement assembly 43 of the load handling device 31. Thus, the power bank 51 can be lifted into the container receiving space 49 of the load handling device 31 in the same manner as the storage container 9 discussed above.

[0053] The load handling device 31 includes a main rechargeable power source 53 which can be a rechargeable battery or a supercapacitor or any other suitable rechargeable power source 53. One or more main rechargeable power sources 53 may be provided within the same load handling device 31.

[0054] When the power bank 51 is lifted by the container lifting means 39 within the container receiving space 49 of the load handling device 31, the power bank 51 can charge the load handling device 31. More specifically, the auxiliary rechargeable power source 55 within the power bank 51 can recharge the main rechargeable power source 53 within the load handling device. The outer casing 57 includes power transmission means configured to transmit power from the auxiliary rechargeable power source 55 within the power bank 51 to the main rechargeable power source 53 within the load handling device 31 when the power bank 51 is received within the container receiving space 49 of the load handling device 31.

[0055] FIG. 9 shows the load handling device 31 and the power bank 51. The load handling device 31 includes a main rechargeable power source 53 and a container receiving space 49, illustrated by dashed lines in FIG. 9. The load handling device 31 includes container engaging means 39 including a container engaging assembly 43 configured to be raised or lowered by four tapes or bands 41. The power bank 51 includes an outer casing 57 and an auxiliary rechargeable power source 55, the latter illustrated by dashed lines in FIG. 9. The container engaging assembly 43 of the load handling device 31 is configured to engage with the power bank 51, specifically the outer casing 57 of the power bank 51.

[0056] The power bank 51 may be a dedicated storage container 9 adapted or configured for charging. The power bank 51 may be the same size as other storage containers 9 within the grid framework structure 1 used for storing products and may similarly interface with the load handling device 31.

[0057] It is advantageous for the voltage of the auxiliary rechargeable power source 55 of the power bank 51 to be lower than the voltage of the main rechargeable power source 53 within the load handling device 31 because this means there is no reverse flow of power from the load handling device 31 to the power bank 51. Supercapacitor as an auxiliary rechargeable power source In some examples, the auxiliary rechargeable power source 55 within the power bank 51 may be a supercapacitor or an assembly of supercapacitors.

[0058] Supercapacitors tend to operate at low voltages, typically around 3 volts. To achieve higher voltages and thus higher energy storage capacity, multiple supercapacitors can be connected in series. For example, if the auxiliary rechargeable power source 55 has a rated voltage of 48V, 16 supercapacitors each of 3V can be arranged in series to achieve the same voltage as the auxiliary rechargeable power source 55.

[0059] Alternatively, a DCDC converter can be used to convert the voltage of the supercapacitor assembly to a voltage appropriate for charging the auxiliary rechargeable power source 55. For example, a boost converter can be operated in constant current mode to boost the supercapacitor voltage. The constant current mode is suitable for use in fast charging.

[0060] Along with the advantage that a lower voltage within the power bank 51 prevents reverse power flow, in a particular example where the auxiliary rechargeable power source 55 within the power bank 51 is a supercapacitor or an assembly of supercapacitors and the main rechargeable power source 53 within the load handling device 31 is a battery, a lower voltage is preferred due to the relative shape of the discharge curves. FIG. 10 shows typical discharge curves for a battery and a supercapacitor. The discharge curve of the supercapacitor is linear for a constant current load and has a square root relationship with the state of charge, while the discharge curve of the battery is non-linear and is followed by a steeper drop after a relatively flat portion. When the load handling device is being charged by the power bank 51, the supercapacitor within the power bank 51 is discharging (the supercapacitor voltage is decreasing) as the battery within the load handling device 31 is charging (the battery voltage is increasing). When the supercapacitor voltage drops below the battery voltage, charging stops. By boosting the voltage of the supercapacitor, it becomes possible to use a larger portion of the operating range of the supercapacitor.

[0061] The controller for DCDC boost converter control sets the current and voltage targets (for example, the voltage target can be the nominal voltage of the rechargeable power source 55 within the load handling device 31). As the supercapacitor discharges and its voltage drops, the current increases. The limiting factor for how low the supercapacitor voltage can drop is the current through the supercapacitor. If the current is too high, it can cause problems related to overheating. In fact, the boost control attempts to meet the target voltage, but when the low supercapacitor voltage is reached, it is limited by the current. A much larger portion of the operating range of the supercapacitor is available for use by the DCDC converter.

[0062] To achieve higher power density and higher energy storage capacity, multiple supercapacitors can be connected in parallel. The main advantage of connecting in parallel is that it is easier to monitor the voltage of the supercapacitors to ensure that the supercapacitors cannot operate at a voltage higher than their rated voltage. That is, when connected in parallel, the voltage only needs to be monitored at two positions, while when connected in series, the voltage needs to be monitored at all points between consecutive supercapacitors in the chain.

[0063] The supercapacitor voltage needs to be carefully managed to ensure that when one supercapacitor operates at a voltage above its rated voltage, which can make the supercapacitor more prone to damage, the voltage remains balanced.

[0064] Thus, a supercapacitor assembly can comprise supercapacitors in series, in parallel, or both. For example, a supercapacitor assembly may comprise a string of supercapacitor elements connected in series, where each element of the string is composed of several parallel capacitors. This arrangement combines the advantage of increasing the voltage and the advantage of facilitating the monitoring of the voltage across each element of the string in order to ensure that the supercapacitor is not allowed to operate above its rated voltage. Such an arrangement is illustrated in FIG. 11.

[0065] The term "supercapacitor" is used broadly to encompass all capacitor technologies. Examples include capacitors, supercapacitors, ultracapacitors, lithium capacitors, electrochemical double layer capacitors, electric double layer capacitors, pseudocapacitors, or hybrid capacitors. Battery as an auxiliary rechargeable power source In other examples, the auxiliary rechargeable power source 55 within the power bank 51 may be a rechargeable battery. Since batteries have the advantage of high energy density, one power bank 51 can be used to fully recharge the load handling device 31 from a low charge level to a fully charged state.

[0066] Examples of rechargeable batteries include, but are not limited to, lithium-ion batteries, lithium-ion polymer batteries, lithium-air batteries, lithium-iron batteries, lithium iron phosphate batteries, lead-acid batteries, nickel-cadmium batteries, nickel-metal hydride batteries, nickel-zinc batteries, sodium-ion batteries, sodium-air batteries, thin-film batteries, smart batteries, carbon foam-based lead-acid batteries.

[0067] Other rechargeable power source technologies are applicable in the present invention. Although specific examples of rechargeable batteries and supercapacitors have been described, any suitable rechargeable power source may be used.

[0068] Similarly, the main rechargeable power source 53 within the load handling device 31 can be a rechargeable battery, a supercapacitor, or any other suitable rechargeable power source. Charging the load handling device The power transfer means 59 of the power bank 51 is configured to transfer power from the power bank 51 to the load handling device 31 in order to charge the load handling device 31. This can be achieved by at least one coupling element. In some examples, the at least one coupling element comprises a primary charging providing element 62 on the power bank 51. The primary charging providing element 62 is configured to transfer power to a charging receiving element 65 on the load handling device 31 in order to charge the main rechargeable power source 53 within the load handling device 31. The primary charging providing element 62 and the charging receiving element 65 can take any suitable form as long as power can be transmitted. For example, power can be transmitted by contact or wirelessly.

[0069] In the case where power is transmitted by contact, the primary charging providing element 62 on the power bank 51 comprises a primary charging providing contact 62, and the charging receiving element 65 on the load handling device 31 comprises a charging receiving contact 65, whereby power is transmitted by contact between the primary charging providing contact 62 and the charging receiving contact 65.

[0070] FIG. 12 shows an example of the load handling device 31 and the power bank 51 when power is transmitted by contact. The load handling device 31 comprises a main rechargeable power source 53 electrically connected to a charging receiving contact 65, and a container engagement assembly 43 that can be raised or lowered by four tapes 38. The container engagement assembly 43 comprises engagement means 42 for engaging with the power bank 51.

[0071] The power bank 51 comprises an auxiliary rechargeable power source 55 electrically connected to a primary charging providing contact 62, and an outer casing 57. The outer casing 57 comprises engagement features 44 for engaging with the engagement means 42 of the load handling device 31.

[0072] To charge the payload handling device 31, the container engagement assembly 43 is lowered by four tapes 38. The engagement means 42 on the container engagement assembly 43 engages with the engagement feature 44 of the power bank 51. When engaged, the power bank 51 is lifted into the container receiving space 49 of the payload handling device 31. When the power bank 51 is lifted into the container receiving space 49, the primary charge providing contact 62 contacts the charge receiving contact 65 of the payload handling device 31, and power is transmitted from the power bank 51 to the payload handling device 31. Power is transmitted from the main rechargeable power source 55 of the power bank 51 to the rechargeable power source 53 of the payload handling device 31 via the primary charge providing contact 62 of the power bank 51 and the charge receiving contact 65 of the payload handling device 31.

[0073] In some examples, control signals can be transmitted between the payload handling device 31 and the power bank 51. These signals can be transmitted using the same primary charge providing contact 62 and charge receiving contact 65, or using different contacts or connectors. When using different connectors, connection blocks can be provided on both the payload handling device and the power bank. The connection block on the power bank 51 includes the primary charge providing contact 62 and a control contact or connector, and the connection block on the payload handling device 31 includes the charge receiving contact 65 and a control contact or connector. Alternatively, the control signals can be transmitted wirelessly.

[0074] When the primary charge providing element 62 and the charge receiving element 65 each include the primary charge providing contact 62 and the charge receiving contact 65, monitoring the state of the contacts can be beneficial. Auxiliary or signal pins can be used to monitor how charging is being transmitted and to stop charging if any potential problems, such as problems related to wiring or overheating, are detected.

[0075] In the case where power is transmitted wirelessly, the primary charging providing element 62 on the power bank 51 includes a wireless charging transmitter, and the charging receiving element 65 on the load handling device 31 includes a wireless charging receiver, whereby power is wirelessly transmitted from the wireless charging transmitter to the wireless charging receiver. Control signals can also be transmitted wirelessly. For example, near field communication (NFC) can be used in combination with wireless charging. Charging through the stack in the storage column When positioned within the stack 11 in the grid framework structure 1, the power bank 51 can be recharged from another power bank 51 below it within the stack 11. The power bank 51 at the bottom of the stack 11 can be recharged from the base charging plate 67 located at the bottom of the stack 11.

[0076] The base charging plate 67 provides an extended solution. The base charging plate 67 can be used to charge a single power bank 51 or the entire stack of power banks 51. The advantage of charging the stack of power banks 51 simultaneously is spatial efficiency. The entire stack of power banks 51 can be recharged simultaneously while occupying only the installation area of one grid space or grid cell 14. This provides even better efficiency than using a charging station on the truck system 13. In the case of a charging station, only one load handling device 31 can be charged at a time, and the space below the grid cell 14 where the charging station is located is effectively "dead space" because access to the storage column 10 below the grid cell 14 is not possible.

[0077] A dedicated charging stack can be used for the power bank 51. In this case, the base charging plate 67 is permanently fixed to the ground at the bottom of the stack 11. Alternatively, for greater flexibility, the stack 11 can be dual-purpose and can be used either for charging or for storage. In some examples, the base charging plate 67 can be movable, whereby the storage column 10 can be used as a dedicated charging column for stacking the power bank 51 (if the base charging plate 67 is present), or the storage column 10 can be used to store the storage container 9 with products when the base charging plate 67 is removed. In other examples, when the stack 11 is not required to be used for charging, the stack 11 can be used for storage with the storage container 9 stacked on top of the base charging plate 67.

[0078] The auxiliary rechargeable power source 55 within the power bank 51 can be periodically replenished when it is within the stack 11.

[0079] To facilitate charging within the stack 11, the power transfer means 59 performs the function of enabling the power bank 51 to receive power and enabling the power bank 51 to provide power to the load handling device 31. The power transfer means 59 comprises at least one electrical coupling element, and in addition to at least one electrical coupling element comprising the primary charging providing element 61, another electrical coupling element may be provided to facilitate the power bank 51 receiving power from the base charging plate 67 and / or providing power to and / or receiving power from another power bank 51.

[0080] FIG. 13 shows an example of a power bank 51 configured to be charged within stack 11. As in the example of FIG. 12, the power bank 51 includes an auxiliary rechargeable power source 55 electrically connected to a primary charge providing contact 62 and an outer casing 57. The power bank 51 further includes a primary charge receiving contact 63 through which the power bank 51 can receive charge from the base charging plate 67.

[0081] In addition to the primary charge providing contact 62 for charging the payload handling device 31 and the primary charge receiving contact 63 for receiving charge from the base charging plate 67, the power bank 51 includes secondary charge providing contacts 64 and secondary charge receiving contacts 66 for providing charge to and receiving charge from another power bank 51 within the stack 11. In some examples, the primary charge providing contact 62 and / or charge receiving contact 63, and the secondary charge providing contact 64 and / or charge receiving contact 66 can be separate elements, and in other examples, the primary charge providing contact 62 and / or charge receiving contact 63, and the secondary charge providing contact 64 and / or charge receiving contact 66 can be the same element. In the example illustrated in FIG. 13, the primary charge providing contact 62 and the secondary charge providing contact 64 are the same, i.e., one charge providing contact serves both the primary function of charging the payload handling device 31 and the secondary function of charging another power bank 51 above it within the stack. Similarly, the primary charge receiving contact 63 and the secondary charge receiving contact 66 are the same, i.e., one charge receiving contact serves both the primary function of receiving charge from the base charging plate 67 and the secondary function of receiving charge from another power bank 51 below it within the stack.

[0082] In the illustrated example, the primary charge supply contact 62 and the secondary charge supply contact 64 are located at the upper part of the upper surface of the power bank 51, and the primary charge receiving contact 63 and the secondary charge receiving contact 66 are located at the lower surface of the bottom surface of the power bank 51. When the power bank 51 is being recharged within the stack 11, the secondary charge supply contact 64 engages with the secondary charge receiving contact 66 of the power bank 51 immediately above (vertically adjacent to) the power bank 51 within the stack 11, and the secondary charge receiving contact 66 of the power bank 51 engages with the secondary charge supply contact 64 of another power bank 51 immediately below (vertically adjacent to) the power bank 51 within the stack 11. Thus, the power bank 51 can simultaneously receive power from the lower power bank 51 within the stack 11 and supply power to the upper power bank 51.

[0083] FIG. 14 shows an example of the power bank 51 and the base charging plate 67. The base charging plate 67 includes a charge supply contact 68 configured to engage with the primary charge receiving contact 63 of the power bank 51. The charge supply contact 68 of the base charging plate 67 is located at the upper part of the upper surface of the base charging plate 67 so that the charge supply contact 68 of the base charging plate 67 is aligned with and engages with the primary charge receiving contact 63 located at the lower surface of the bottom surface of the power bank 51.

[0084] FIG. 15 shows an example of a stack 11 having a base charging plate 67 and three power banks 51. In the following description, the three power banks 51 are defined as a first power bank 51a, a second power bank 51b, and a third power bank 51c. The reference symbols a, b, and c are used to indicate the first, second, and third power banks 51 respectively, and their components. The first power bank 51a is located within the center of the stack 11. The second power bank 51b is at the bottom of the stack 11 immediately below the first power bank 51a. The third power bank 51c is at the top of the stack 11 immediately above the first power bank 51a. Each of the first, second, and third power banks 51a, 51b, 51c includes secondary charging supply contacts 64a, 64b, 64c located on the upper surfaces of their respective power banks 51a, 51b, 51c, and secondary charging receiving contacts 66a, 66b, 66c located on the lower surfaces of the lower surfaces of their respective power banks 51a, 51b, 51c.

[0085] The first power bank 51a receives power from the second power bank 51b immediately below the first power bank 51a within the stack 11. More specifically, the secondary charging receiving contact 66a of the first power bank 51a receives power from the secondary charging supply contact 64b of the second power bank 51b.

[0086] The first power bank 51a transmits power to the third power bank 51c immediately above the first power bank 51a within the stack 11. More specifically, the secondary charging supply contact 64a of the first power bank 51a transmits power to the secondary charging receiving contact 66c of the third power bank 51c. Thus, the first power bank 51a at the center of the stack 11 simultaneously receives power from the second power bank 51b and provides power to the third power bank 51c. Power is transmitted upward through the stack of power banks 51.

[0087] The second power bank 51b at the bottom of the stack 11 receives power from the base charging plate 67. More specifically, the primary charge receiving contact 63b of the second power bank 51b receives power from the charge providing contact 68 of the base charging plate 67. In the illustrated example, the primary charge receiving contact 63b and the secondary charge receiving contact 66b of the second power bank are the same contact.

[0088] The arrows on FIG. 15 indicate the direction of power transmission. Power is transmitted upward from the base charging plate 67 through each of the power banks 51 in turn, and each power bank 51 within the stack 11 receives power from below within the stack 11 and transmits the power to the power bank 51 above.

[0089] In the example illustrated in FIGS. 12 - 15, the charge providing contact 68 of the base charging plate 67 is of the same design as the primary charge providing contact 62 and the secondary charge providing contact 64 of the power bank 51, and the primary charge receiving contact 63 and the secondary charge receiving contact 66 of the power bank 51 are of the same design as the charge receiving contact 65 of the load handling device 31. The electrical contacts are horizontally aligned when the power bank 51 is within the stack 11. Thus, the power bank 51 is interchangeable and can receive power either from the base charging plate 67 or from another power bank 51 below within the stack 11, and can provide charging either to the load handling device 31 or to another power bank 51 above within the stack 11.

[0090] In other examples, the power bank 51 may be provided with a separate primary charge providing contact 62 for charging the load handling device 31 and a separate secondary charge providing contact 64 for charging another power bank 51, rather than a single charge providing contact that serves both functions.

[0091] In the example illustrated in FIGS. 12 - 15, power is transmitted by contact between the charge providing contact and the charge receiving contact. In other examples, the power transmission means 59 may comprise other means for transmitting power, such as by wireless power transmission. Location and Distribution of Charging Columns In a large-scale storage system, multiple dedicated charging stacks may be required to ensure that there is a power bank 51 sufficient to keep all the handling devices 31 charged without the need for external chargers.

[0092] The charging stacks may be evenly distributed within the grid framework structure 1 to ensure that the handling device 31 can be anywhere on the truck system 13 and not too far from the charging columns. Alternatively, the charging stacks may be located near the port columns to reduce the travel time of the handling device 31. Alternatively, the charging stacks may be located further away from the port columns so that the handling device 31 being charged can charge without interfering with the path of the handling device 31 fulfilling a customer order and / or to efficiently use the available space and minimize the distance between the port columns and the storage containers 9 picked up by the handling device 31, enabling the use of the storage columns 10 closer to the port columns for the storage of stacks of containers 9. Alternatively, the charging stacks may be located at the edge of the grid framework structure 1 so that the base charging plate 67 of the charging stack can be easily accessed for maintenance. The location and distribution of the charging stacks within the grid framework structure 1 can be any of the above, or a combination of any of the above. The optimal location and distribution of the charging stacks may depend on the size and layout of the grid framework structure 1, the number of handling devices 31, and the speed of the customer order processing capacity. Bypass Charging In some examples, it is possible to bypass the charging method described above, in which power is transmitted upward through the stack of power banks 51 in stack 11 by each power bank 51 charging the power bank 51 above it in the stack. Thereby, a power bank 51 within stack 11 that is not at the bottom of stack 11 can be directly charged from the base charging plate 67 rather than being charged from the power bank 51 immediately below it within stack 11. This can be useful, for example, when the power bank 51 at the top of stack 11 needs to be charged first, such as when the load handling device 31 urgently requires charging and it is not desirable to wait until the entire stack of power banks 51 within stack 11 is fully charged.

[0093] Bypass charging can act through the same electrical contacts as described above, where power is transmitted from the charge providing element 68 on the base charging panel 67 or the secondary charge providing element 64 on another power bank 51 immediately below within stack 11 to the secondary charge receiving element 66 of the power bank 51. Each power bank 51 may be provided with a bypass mechanism that conducts power from the primary charge receiving element 63 or the secondary charge receiving element 66 to the secondary charge providing element 64 while bypassing the rechargeable power source 55 within the power bank 51. Thus, power can be transmitted from the base charging plate 67 at the bottom of stack 11 through the chain of all charge receiving elements 63, 66 and secondary charge providing elements 64 of the power banks 51 within the stack to the power bank 51 at the top of the stack. The rechargeable power source 55 within the power bank 51 at the top of the stack is charged without requiring that all the rechargeable power sources 55 of the other power banks 51 below within the stack be charged first.

[0094] In some examples, the bypass mechanism within the power bank 51 may split the current received from the base charging plate 67 or from the power bank 51 below the stack 11 such that a portion of the current is used to charge an auxiliary rechargeable power source 55 within the power bank 51 and the remaining portion of the current is transmitted to the upper power bank 51 within the stack 11. Thus, the power bank 51 can simultaneously charge and pass power upward within the stack 11. Bus bar charging Optionally, a bus bar may be provided as an alternative to or in addition to the base charging plate 67 to charge the power banks 51 within the charging stack. Optionally, the bus bar may be integrated within the upright members 3 of the grid framework structure 1. Since all of the power banks 51 within the stack 11 can contact the bus bar, any power bank 51 can be directly charged from the bus bar regardless of its position within the stack 11. A control system is provided to control the amount of current that each power bank 51 draws from the bus bar. The bus bar has the advantage of overall flexibility in charging. Any power bank 51 at any position within the dedicated charging stack 61 can be charged.

[0095] The bus bar may be for rapid charging, using a higher current than charging through the base charging plate 67 or charging from another power bank 51 as described above. Rapid charging may be provided by a buck converter in constant current mode that converts a higher voltage supply at the bus bar of the stack 11 to a lower voltage for charging the power bank 51.

[0096] The power bank 51 may be provided with separate electrical contacts located on the side of the power bank 51 to facilitate charging from the bus bar.

[0097] Fast charging is particularly effective in the case where the auxiliary rechargeable power source 55 within the power bank 51 is a supercapacitor, because a supercapacitor can receive a higher current than a rechargeable battery. Control system One or more control systems may be provided to perform functions including, but not limited to, controlling the movement of the load handling device 31 on the track system 13, tracking the charge level of the main rechargeable power source 53 within the load handling device 31, tracking the charge level of the auxiliary rechargeable power source 55 within the power bank 51, identifying where on the track system 13 the load handling device 31 should go during charging, controlling when and how to remove the power bank 51 from the grid framework structure 1, controlling the bypass mechanism of the power bank 51, and controlling how much current the power bank 51 can draw from the bus bar. These operations may be performed by the same control system or by different control systems.

[0098] To ensure that the load handling device 31 is charged when needed, the control system can monitor the charge states of the load handling device 31 and the power bank 51. This can be achieved in several different ways. For example, the load handling device 31 and the power bank 51 can send signals indicating their charge states to the control system.

[0099] Alternatively, the control system can ensure that a given power bank 51 can be recharged for a predetermined length of time before being reused to charge the load handling device 31. Even a power bank 51 that has not been fully charged can still send a partial charge to the load handling device 31. If the load handling device 31 is not fully charged after charging from the power bank 51, the load handling device 31 can communicate to the control system that further charging is required, and the control system can then direct the load handling device 31 to pick up another power bank 51.

[0100] Alternatively, the power banks 51 can communicate their charging states to the control system either directly via the base charging plate 67 or via other power banks 51 within the stack 11 above the base charging plate 67. The control system can select the power bank 51 with the highest state of charge, or the power bank 51 that has been charged for the longest time, to be used to charge the next load handling device 31 that requires charging.

[0101] The control system may also monitor the state of the electrical contacts, for example, to detect problems related to wiring or overheating. Size, capacity, and type of storage container The power bank 51 can be the same height as the storage container 9. Alternatively, the power bank 51 can be lower in height than the storage container 9, in which case a greater number of power banks 51 can fit within the stack 11. For example, if the power bank 51 is half the height of the storage container 9, twice the number of power banks 51 of the storage container 9 within the stack 11 can fit within the stack 11.

[0102] To provide greater flexibility with respect to charging, the system may include power banks 51 having different energy storage capacities. For example, two capacities of the power bank 51, namely a first capacity of the power bank 51 having a greater storage capacity and a second capacity of the power bank 51 having a lesser storage capacity, may be provided. The two capacities of the power bank 51 may be stored in different stacks 11 or together in the same stack 11. The first capacity of the power bank 51 may be used when the load handling device 31 requires a full charge. The second capacity of the power bank 51 is adapted for lower charging requirements, such as when the load handling device 31 requires a partial charge, or for shorter charging opportunities, such as when the load handling device 31 has only a short time for charging before being required for its next operation. The main advantage of providing different capacities of the power bank 51 with different energy storage capacities is flexibility in charging. Regardless of whether the load handling device 31 requires a partial charge or a full charge, the power bank 51 is available to deliver an appropriate amount of charge and the full capacity of the power bank 51 can be utilized.

[0103] In some examples, the two capacities of the power bank 51 have different dimensions. The first capacity of the power bank 51 has the same dimensions as a standard storage container 9, and the second capacity of the power bank 51 is half the height of the standard storage container 9. The second capacity of the power bank 51 includes a smaller auxiliary rechargeable power source 55 than the first capacity, and thus requires less space for packaging the auxiliary rechargeable power source 55 and other components. Since the shorter power bank 51 occupies less space, more can be stored in the stack 11. This makes it possible to provide more power banks 51 than the number of load handling devices 31 required within the system, and thus more load handling devices 31 can be charged during downtime.

[0104] Alternatively or additionally, a power bank 51 of a different energy storage type may be provided. For example, in a first type of power bank 51, a supercapacitor having the advantages of high power density and fast charging speed may be provided as the main rechargeable power source 55. In a second type of power bank 51, one or more batteries having the advantage of higher energy storage capacity may be provided as the main rechargeable power source 55. This provides further flexibility in charging. When the load handling device 31 requires fast charging, it can draw on the first type of power bank 51 and charge quickly from the supercapacitor power source, and when the load handling device 31 requires slower or larger charging, it can draw on the second type of power bank 51 and charge more slowly from the battery power source.

[0105] It will be appreciated that many different combinations of different capacities, sizes, types, and charging speeds of the power banks 51 are possible. All of the power banks 51 interface with the load handling device 31 in the same way as the standard storage container 9, and all of the power banks 51 interface with each other and with the base charging plate 67 in the same way. Ambient temperature The storage and retrieval system may have different sections operating at different temperatures to store products having different temperature requirements. For example, the storage and retrieval system may have a section for merchandise at ambient temperature, a section for chilled merchandise at a lower temperature, and a section for frozen merchandise.

[0106] The auxiliary rechargeable power source 55 within the power bank 51 is a battery, and in the example where the ambient temperature is low, there are additional considerations. For example, when the battery is at a low temperature, it needs to be warmed by slowly charging until the battery cells reach a specific positive temperature, after which the battery cells can be charged more rapidly. Thus, in areas with a lower ambient temperature, the load handling device 31 is more likely to hold the power bank 51 for a longer time period. Therefore, in low-temperature areas, a larger number of power banks 51 may be provided. Method for charging a power source FIG. 16 is a flowchart showing a method for charging the main rechargeable power source 53 within the load handling device 31. Charging the main rechargeable power source 53 may be required, for example, when the main rechargeable power source 53 is depleted and does not have sufficient charge to power the drive mechanism 38 of the load handling device 31.

[0107] In a first step 100, the load handling device 31 picks up the power bank 51 and lifts it into the container receiving space 49 of the load handling device 31. In some examples, the load handling device 31 can carry the power bank 51 to different parts of the grid. The load handling device 31 can move, for example, to a part of the truck system 13 that is not currently in use so as not to interfere with other load handling devices 31 that are retrieving storage containers 9 to fulfill customer orders. Alternatively, a specific charging area may be provided on the truck system 13. In some examples, these specific charging areas can be located near a data exchange point (such as LifeFi) so that the load handling device 31 can upload data or download updates while charging.

[0108] The payload handling device 31 can utilize charging opportunities that do not reduce the time available for executing operations on the grid framework structure 1. For example, the payload handling device 31 can obtain the power bank 51 while moving to different parts of the track system 13 as preparation for performing another operation, or while waiting for another payload handling device 31 to retrieve a storage container 9 above the target storage container 9 in the stack 11, or while the demand for the payload handling device 31 to retrieve the storage container 9 has subsided.

[0109] In the second step 102, the power bank 51 charges the main rechargeable power source 53 of the payload handling device 31. Since the auxiliary rechargeable power source 55 in the power bank 51 can be selected to have the advantages of a high power density (e.g., supercapacitor), the charging is performed over a relatively short period of time. This reduces or eliminates the need for downtime while charging. Depending on the charging capacity and state of the main rechargeable power source 53 of the payload handling device 31, two or more power banks 51 may be required to fully charge the main rechargeable power source 53 within the payload handling device 31.

[0110] Alternatively, the auxiliary rechargeable power source 55 in the power bank 51 can be selected to have the advantages of a high energy density (e.g., rechargeable battery). This can have the advantage that a single power bank 51 can provide a full charge to the main rechargeable power source 53 of the payload handling device 31.

[0111] In the third step 104, the payload handling device 31 returns the power bank 51 to the stack 11 within the grid framework structure 1. This stack can be the same stack 11 or a different stack 11 where the power bank 51 was previously located.

[0112] In the fourth step 106, the auxiliary rechargeable power source 55 in the power bank 51 is recharged within the grid framework structure 1.

[0113] Figure 17 is a flowchart showing a method in which the first load handling device 31 takes the power bank 51 to a predetermined location and then the second load handling device 31 is charged from the power bank 51. Again, charging the main rechargeable power source 53 of the second load handling device 31 may be necessary, for example, when the main rechargeable power source 53 is partially depleted and does not have enough charge to power the drive mechanism 38 of the second load handling device 31 to move to another power bank 51 or a charging station.

[0114] In a first step 110, the load handling device 31 picks up the power bank 51 and lifts it into the container receiving space 49 of the first load handling device 31.

[0115] Optionally, in a second step 112, the power bank charges the first load handling device 31.

[0116] In a third step 114, the first load handling device 31 takes the power bank 51 to a predetermined location within the grid framework structure 1. The predetermined location can be a grid cell adjacent to or near the second load handling device 31. Advantageously, this method allows the second load handling device 31 to easily reach the power bank 51 without having to travel to another power bank or a remotely located charging station, for example, on a different part of the truck structure 13. For example, if the main power source 53 of the second load handling device 31 is partially depleted and has only enough charge to move a short distance, the second load handling device 31 may be able to move to the predetermined location rather than becoming immobile on the truck system 13 because it does not have enough power to travel to another power bank 51 or a charging station.

[0117] In the fourth step 116, the second load handling device 31 picks up the power bank 51. Since the predetermined location can be selected to be adjacent to or near the second load handling device 31, the second load handling device 31 does not travel far.

[0118] In the fifth step 118, the power bank 51 charges the second load handling device.

[0119] The method may further comprise a step (not shown) in which the second load handling device returns the power bank to a stack within the grid framework structure, and the power bank is recharged within the grid framework structure.

[0120] The advantages of the power banks 51 are that they are a less expensive solution than charging or swapping stations for the main rechargeable power source 53, fit within the existing grid framework structure 1 without the need for special devices that greatly reduce the available storage space.

[0121] Another advantage is that the power banks 51 can be easily serviced and maintained. A power bank 51 that requires maintenance can be picked up by the load handling device 31 and removed from the grid framework structure 1, where it can be transported to a maintenance area. Definition In this document, the phrase "movement in the n direction" (and related turns of phrase), where n is one of x, y, and z, is intended to mean movement substantially along or parallel to the n axis in either direction (i.e., towards the positive end of the n axis or towards the negative end of the n axis).

[0122] In this document, the words "connect" and its derivatives are intended to include 25 possibilities of direct and indirect connection. For example, "x is connected to y" is intended to include the possibility that x is directly connected to y without intervening components and the possibility that x is indirectly connected to y with one or more intervening components. When a direct connection is intended, the words "directly connected", "direct connection" or similar expressions are used. Similarly, the words "support" and its derivatives are intended to include the possibility of direct and indirect contact.

[0123] For example, "x supports y" is intended to include the possibility that x directly supports y without intervening components and directly contacts it, and the possibility that x indirectly supports y with one or more intervening components that contact x and / or y. The words "attach" and its derivatives are intended to include the possibility of direct and indirect attachment. For example, "x is attached to y" is intended to include the possibility that x is directly attached to y without intervening components and the possibility that x is indirectly attached to y with one or more intervening components.

[0124] In this document, the words "comprise" and its derivatives are intended to have an inclusive rather than an exclusive meaning. For example, "x comprises y" is intended to include the possibility that x includes one and only one y, a plurality of y, or one or more y, and one or more other elements. When an exclusive meaning is intended, the expression "x consists of y" is used, which means that x includes only y and no others.

[0125] In this document, the term "fully charged" as applied to a rechargeable power source means that the rated charge is provided to the rechargeable power source. For a battery, this means that the battery voltage is the rated voltage. The term "depleted" as applied to a rechargeable power source means that a predetermined residual charge remains in the rechargeable power source. For a battery, this means that the battery voltage has dropped below the rated power to a predetermined residual voltage.

Claims

1. A power bank (51) for charging a load handling device (31), the power bank comprising: an auxiliary rechargeable power source (55); at least one power transfer means (59) electrically coupled to the auxiliary rechargeable power source; The at least one power transfer means is configured to be electrically coupled to the load handling device for transferring power from the auxiliary rechargeable power source to the load handling device. Power bank (51).

2. The at least one power transfer means (59) comprises at least one electrical coupling element, the at least one electrical coupling element comprising a primary charging providing element (62) configured to electrically couple the power bank to the load handling device (31). The power bank (51) according to claim 1.

3. The power bank according to claim 1 or 2, wherein the power bank comprises an outer casing (57) configured to be received within the load handling device (31). (51).

4. The power bank (51) according to claim 3, wherein the outer casing (57) comprises one or more engagement features (44) configured to be engaged by the load handling device (31).

5. The power bank (51) according to claim 3 or 4, wherein the outer casing (57) comprises a base, side walls, and an opening for receiving the auxiliary rechargeable power source (55).

6. The power bank (51) according to claim 5, dependent on claim 4, wherein the engagement feature (44) comprises one or more openings within the side wall of the outer casing (57).

7. The power bank (51) according to any one of claims 1 to 6, wherein the auxiliary rechargeable power source (55) within the power bank comprises one or more supercapacitors.

8. The power bank (51) according to claim 7, wherein the one or more supercapacitors comprise a plurality of supercapacitor elements connected in series, each supercapacitor element comprising a plurality of supercapacitors connected in parallel.

9. The power bank (51) according to any one of claims 1 to 8, wherein the auxiliary rechargeable power source (55) comprises a rechargeable battery.

10. The power bank (51) according to any one of claims 1 to 9, further comprising a voltage converter for converting the voltage from the auxiliary rechargeable power source (55) in the power bank to charge the load handling device (31).

11. The power bank (51) according to claim 10, wherein the voltage converter comprises a DC-DC boost converter.

12. The at least one electrical coupling element further comprises a secondary charge providing element (64) for electrically coupling to vertically adjacent power banks in the stack (11), such that when arranged in a stack of power banks, power can be transmitted from the power bank to a vertically adjacent power bank. The power bank (51) according to any one of claims 2 to 11.

13. The at least one electrical coupling element further comprises a secondary charge receiving element (66) for electrically coupling to vertically adjacent power banks in the stack, such that when arranged in a stack of power banks, power can be transmitted from a vertically adjacent power bank to the power bank. The power bank (51) according to any one of claims 2 to 12.

14. A load handling device (31), 1) a main rechargeable power source (53), 2) a container receiving space (49) configured to receive the power bank (51) according to any one of claims 1 to 13, 3) a container engagement assembly (43) configured to engage with the power bank, and a drive mechanism (38) configured to lift the power bank into the container receiving space. A container lifting device (39) comprising: The load handling device is configured to receive power from the power bank when the power bank is received in the container receiving space of the load handling device.

15. The load handling device according to claim 14, wherein the container receiving space (49) comprises a charge receiving element (65) for receiving power from the power bank (51) to charge the main rechargeable power source (53).

16. The load handling device (31) according to claim 14 or 15, dependent on claim 3, wherein the container engagement assembly (43) comprises one or more grippers, and the outer casing (57) is configured to be gripped by the grippers.

17. A storage and collection system, comprising: A) A grid framework structure (1), wherein the grid framework structure comprises: i) A track system (13) comprising a plurality of tracks (17, 19) arranged in a grid pattern; ii) A support framework structure (2) for supporting the track system; iii) A plurality of stacks (11) of storage containers (9) arranged in a plurality of storage columns (10) located below the track system; B) A load handling device (31) according to any one of claims 14 to 16, wherein the container receiving space (49) is further configured to receive a storage container, the container engagement assembly (43) is further configured to engage with the storage container, and the drive mechanism (38) is further configured to lift the storage container from a stack among the plurality of stacks into the container receiving space. Comprising: A storage and collection system, wherein one or more of the storage containers in the stack are power banks (51) according to any one of claims 1 to 13.

18. The storage and collection system according to claim 17, dependent on claim 3, wherein the outer casing (57) has substantially the same dimensions as the storage container (9).

19. The storage and collection system according to claim 17 or 18, wherein one or more of the storage columns (10) comprise a charging surface, and the charging surface comprises a charging providing element (68) for charging the power bank when the charging surface is electrically coupled to the power bank (51).

20. The storage and collection system according to claim 19, wherein the charging surface comprises a base charging plate (67), whereby the power bank (51) is electrically coupled to the base charging plate when the power bank is mounted on the base charging plate.

21. The storage and recovery system according to claim 19, wherein the charging surface comprises a bus bar (73) extending upward along the storage column (10), whereby the bus bar (73) is electrically coupled to a side surface of the power bank (51).

22. The storage and recovery system according to any one of claims 19 to 21, further comprising a primary charge receiving element (63) configured to receive power from the charge providing element (68) of the charging surface, wherein the at least one electrical coupling element of the power bank (51).

23. The storage and recovery system according to any one of claims 14 to 22, dependent on claims 12 and 13, comprising a plurality of power banks (51) arranged in a stack (11), wherein secondary charge providing elements and charge receiving elements (64, 66) of each of the power banks are electrically coupled to each other within the stack to transfer charge between vertically adjacent power banks within the stack.

24. A method for transferring power to a load handling device (31) operable within a storage and recovery system according to any one of claims 17 to 23, the method comprising: a) moving the load handling device on the track system (13) to a location above a stack (11) comprising a power bank (51); b) using the container lifting means (39) to lift the power bank into the container receiving space (49) of the load handling device such that at least one power transfer means (59) is electrically coupled to the charge receiving element (65) of the load handling device so that power is transferred from the auxiliary rechargeable power source (55) within the power bank to the main rechargeable power source (53) of the load handling device.

25. The method according to claim 24, further comprising: c) the load handling device returning the power bank to a stack within the grid framework structure.

26. The method according to claim 25, further comprising: d) the power bank being recharged within the stack of the grid framework structure (1).

27. A method for transmitting power to a load handling device (31) operable within a storage and retrieval system according to any one of claims 17 to 23, wherein the storage and retrieval system comprises a first load handling device and a second load handling device, the method comprising: a) moving the first load handling device on the track system (13) to a location above a stack (11) comprising a power bank (51); b) using the container lifting means (39) to lift the power bank into the container receiving space (49) of the first load handling device; c) moving the first load handling device on the track system to a predetermined location; d) returning the power bank to the stack below the target location within the grid framework structure by the first load handling device; e) lifting the power bank into the container receiving space by the second load handling device such that power is transmitted from the auxiliary rechargeable power source (55) within the power bank to the main rechargeable power source (53) of the second load handling device.

Images