Lift-free storage facilities

Abstract

A storage facility (1) has a plurality of storage racks (R) and storage rack tiers (3) for storing load units (T), wherein an aisle (2) is provided between two storage racks (R), each storage rack tier is provided with running rails on opposite sides of the storage rack (R) on which at least one storage and retrieval device (5) is movable along the length of the aisle (2), and each aisle (2) is provided with at least two pairs of vertical lifting rails on opposite sides of the storage rack (R) adjacent to the respective aisle (2). The storage and retrieval device (5) has a transport area for at least one load unit (T), which is located between unit handling means for loading and unloading the load unit (T) into the storage rack (R), and the unit handling means can extend within the storage rack (R) in a direction perpendicular to the length of the aisle (2). Each of the storage and retrieval devices (5) has a first set of four moving wheels for moving horizontally along running rails along each storage rack level (3) of the aisle (2), with two wheels per set on each side of the storage and retrieval device (5), one or both of which are driven on joint drive shafts, and each of the storage and retrieval devices (5) has climbing means for moving vertically, particularly along vertical lifting rails, to achieve three-dimensional movement of the storage and retrieval device.

Description

[Technical Field]

[0001] The present invention relates to a storage facility according to the preamble of claim 1.

[0002] When picking or compiling an order from picked transport units (goods, containers, etc.), it is necessary to target, sort, and serve the transport units associated with a common order. For this purpose, transport units for one order are usually temporarily stored (buffered) until all the transport units required for the order are available. The transport units are then handed over together to a collection line, where they are directed to the palletization area, picking station, goods outbound department, dispatch, etc.

[0003] A (high) rack storage facility includes a supply area or storage entrance area where goods are delivered and where the rack service unit collects them for entry into the storage area (the so-called pre-zone). Similarly, a retrieval area from the storage area is also required, where the rack service unit also places goods assigned to the pre-zone after retrieving them from the storage area. In automated picking warehouses, the picking point is usually located in the pre-zone. The pre-zone is also where the goods are identified in the inventory management system or material flow computer.

[0004] The applicant's EP 1 964 792 B1 discloses a method for supplying transport units from a storage facility in a desired sequence on at least one collection line, wherein the rack supply units of each storage rack aisle, the storage pick-up lifts and the storage pick-up supply lines are controlled to be coordinated with one another so that the goods are loaded and finally sorted on or delivered by the collection line.

[0005] It is therefore clear that control and regulation are relatively complex and require technical installations in the so-called pre-zone, i.e. in the area outside the actual rack.

[0006] US 9,452,886 B2 discloses direct exchange of transport units from one access aisle to a specific aisle between adjacent storage racks via a lateral transport position on the storage rack itself, wherein the storage and retrieval vehicle is provided with a shuttle at each level of the storage rack, and the direct exchange includes the shuttle acting on the transport unit to move the transport unit from one of the adjacent racks to another of the adjacent racks by contacting the shuttle at the lateral transport position, and the lateral position is used to transfer the product transport unit to a specific aisle.

[0007] However, in contrast to the shuttle, the lift would be the bottleneck of such a system.

[0008] DE 20 2004 012 021 U1 discloses a storage system with at least one conveyor having a horizontal transport unit and performing vertical or vertical and horizontal movement between two shelf rows arranged one behind the other. The storage system includes at least one of two or more shelf rows arranged one behind the other and separated from each other by respective feed shafts equipped with conveyors. Each conveyor is movable on both sides of each shelf row, while all compartments of these shelf rows can be directly loaded or emptied.

[0009] EP 3 609 814 B1 discloses an order picking system including an automatically guided trolley that can travel along the warehouse floor and also climb the surface of the racks. In this system, the trolley has at least two rotating wheels and motorized climbing means formed by a gear carrier that can interact with two pairs of posts so that the trolley can climb along the posts. Each post is fitted with a roller chain that extends parallel to the longitudinal axis of the post to which it is attached, the roller chain being designed to receive a gear that cooperates with the post to which it is attached, and each movable support has means for rigidly connecting to one of the four posts to maintain a predetermined distance between the gear axis and the chain. This system is complicated by the possibility of chain movement.

[0010] In contrast, it is an object of the present invention to provide a storage facility that alleviates the bottlenecks caused by lifts while at the same time allowing efficient handling of storage units in racks.

[0011] This object is achieved by a storage as defined in claim 1. Preferred embodiments are defined in the dependent claims.

[0012] The present invention recognizes that if each storage and retrieval device is equipped with a means for vertical movement, particularly lifting along vertical lifting rails, then storage densities with high access rates can be achieved without the need for dedicated lifts. Furthermore, the present invention provides scalability and flexibility, as the number of storage and retrieval devices (such as shuttles) can be easily adjusted according to capacity needs and storage location size.

[0013] It is also possible to retrofit existing storage by retrofitting existing systems to add vertical movement means, such as adding vertical lift rails to the end areas of traditional racks. This can be done by replacing the lift with lift rails or by attaching lift rails to the original lift frame.

[0014] Vertical lifting rails can be installed, for example, instead of or in addition to conventional lifts. Naturally, there can be several lifting rail sections in a rack. These can be located at the end sections of the aisles, but also in the middle sections, which increases throughput in long aisles.

[0015] The system can accommodate a variety of cargo carriers, including tote bags, trays, and cartons.

[0016] A further advantage is that orders can be consolidated within the storage rack, simplifying ground or conveyor-based movement outside the rack, since storage and retrieval equipment does not need to leave the aisle to change storage levels. Thus, sequencing and buffering of load vehicles is possible at all levels.

[0017] The present invention realizes an easy roaming principle without additional equipment or height restrictions.

[0018] The system of the present invention has few single points of failure, but requires dedicated lifts such as totes, bots, and shuttles.

[0019] In a preferred embodiment, the lifting means of the storage and retrieval device includes a set of four lifting wheels that interact with a vertical lifting rail, the four lifting wheels having a vertical axis of movement compared to the four traveling wheels, the four lifting wheels being retractable between an extended, engaged position for interacting with the vertical lifting rail and a retracted, non-engaged position while moving horizontally along the running rail along the respective storage rack level. Such lifting wheels can be retrofitted to known storage and retrieval devices.

[0020] Each storage and retrieval device may have a second set of four or more retractable travel wheels for moving along direction change rails horizontally along each storage rack level of the aisle in the area of ​​the vertical lifting rail, with two wheels per set on each side of the storage and retrieval device, one or both on each side driven, for example, on an articulated drive shaft, for use in changing the direction of movement of the storage and retrieval device from vertical movement along the vertical lifting rail to horizontal movement along running rails at each storage rack level of the aisle.

[0021] The four transport wheels that move along the direction change rails horizontally along each storage rack level of the aisle in the area of ​​the vertical rails are preferably retractable wheels that are controlled to retract and extend to their use positions while the storage and retrieval device is moving along the direction change rails, and their position on the storage and retrieval device is at a distance and arranged such that they can interact with the direction change rails when changing direction of travel.

[0022] The turning rails can be disposed between the vertical lifting rails at each level having running rails, and the running rails at each storage rack level of the aisle can have a gap with the turning rail horizontally along each storage rack level of the aisle in the region of each vertical rail, thereby enabling easy and smooth turning from vertical to horizontal (or vice versa).

[0023] So essentially, the storage and retrieval device climbs a vertical lift rail using extended lift wheels. As soon as it reaches the desired level, the travel wheels for travel along the direction change rails are extended and engage with the direction change rails. The lift wheels can then be retracted. The storage and retrieval device moves horizontally along these rails (just a few centimeters) until the first set of four travel wheels for travel along the running rails horizontally engage with the running rails of the aisle. Meanwhile, the secondary travel wheels for travel along the direction change rails lose traction and can be retracted.

[0024] Advantageously, the running rail and the diverting rail are aligned with each other, and preferably both the running rail and the diverting rail have a C-shaped cross section, the upper surface of which forms the support for the first set of moving wheels and the inner lower surface of which forms the support for the second set of moving wheels.

[0025] Furthermore, a cross-aisle running rail can be implemented to form a bridge perpendicular to the aisle direction, allowing each storage and retrieval device to move between aisles, preferably propelled by a set of four lifting wheels, so that the storage and retrieval device can change aisles without leaving the rack.

[0026] In one possible embodiment, the lifting wheels are gears (pinions) and the vertical rails and / or cross aisle running rails have corresponding straight gears (racks) or chains, which provide a positive interaction.

[0027] In one embodiment, the gear (pinion) may be implemented as self-locking (e.g., due to the weight of the storage and retrieval device) to stop the storage and retrieval device in the event of a (power) failure due to uncontrolled vertical movement or a collision. To do this, the gear may be attached to the storage and retrieval device frame with a pivoting arm to achieve a wedge-like function. Additionally, the gear may be equipped with a mechanical fail-safe brake, which will hold the storage and retrieval device in its current position even if power or control is lost, as long as the pinion is locked.

[0028] Of course, different lifting means can be used, for example the lifting wheels can be implemented as wheels that press against a vertical rail with enough force to create enough friction to prevent the loading area from sliding downwards when loaded.

[0029] The storage facility may include the capability of directly horizontally exchanging load units from one aisle to an adjacent aisle via an exchange location in the storage rack, and the storage and retrieval device itself actively moves the transport units horizontally within the exchange location using unit (or load) handling means, preferably a telescopic arm having engageable unit (or load) contact means (i.e., rotatable or linearly movable fingers). In this way, the load units are transferred from one aisle to an adjacent aisle via the shortest route without having to leave the aisle or for the storage and retrieval device to leave the aisle.

[0030] The rack preferably has an interface to a conveyor in the pre-zone or front zone of the fulfillment area for connection to any picking station from the bottom to the top. At least one per aisle is preferred. More than one per aisle is possible. Obviously, it is also possible, but not limited to, to have multiple fulfillment areas, for example at different levels, both individually connected to the rack in the manner described above.

[0031] In a preferred embodiment, the storage rack has at least one interface that allows for the handoff of unit loads to an AMR (Autonomous Mobile Robot) for ground transport. This allows for great flexibility in handing off unit loads for transport outside the rack, as the AMR is not tied to rails or a predetermined route. Such an interface may be present in at least one aisle, multiple aisles, or all aisles.

[0032] The storage facility may also include ground transport AMRs (AMR shuttle movers) that can transport storage and retrieval equipment within the storage location, preferably between aisles. This allows for flexible use of storage and retrieval equipment within the overall rack. For example, it is possible to address imbalances in retrieval volume in each aisle or to increase or decrease the number of storage and retrieval equipment depending on customer throughput. For example, some storage and retrieval equipment can be provided that is not dedicated to an aisle, and the present invention can be used for aisle changes. Later, as throughput needs increase, more storage and retrieval equipment can be installed, requiring fewer aisle changes.

[0033] To increase storage capacity and density, the storage facility may include a storage and retrieval device (stacker shuttle) with stacking means for stacking and unstacking load units (preferably containers or totes) on top of each other in its transport area, thereby allowing the stacked load units to be stored and potentially transported.

[0034] Additionally, at least one conventional lift may be incorporated into the system, allowing conventional storage and retrieval equipment to be used in parallel with the bidirectional transfer storage and retrieval equipment of the present invention and increasing the vertical throughput of the system.

[0035] Multiple storage and retrieval devices can be installed on one level of a storage rack aisle to increase throughput. The number of storage and retrieval devices should be linked to the length of the aisle. Usually, two storage and retrieval devices are sufficient. The storage and retrieval devices are equipped with sensors and controls to coordinate the transfer areas between storage and retrieval devices on the same level.

[0036] The present invention allows rescue of a failed storage and retrieval device. A failed storage and retrieval device (e.g., a shuttle) can be rescued by using another storage and retrieval device to push it to the rear end of the rack aisle, as long as its unit handling means is not in an extended position within the storage rack.

[0037] At least two sets of lifting wheels may be provided with bumpers facing the direction of travel along the aisle to contact and push against each pair of lifting wheels of the second storage and retrieval device, facilitating rescue operations. Alternatively or additionally, the housing may be equipped with bumpers on the front and / or rear.

[0038] Preferably, each aisle has at least four sets of vertical lift rails on opposite sides of the storage racks adjacent to each aisle, allowing access from both sides of the aisle depending on the arrangement, and one set can be used for upward movement and one set for downward movement, improving throughput and redundancy.

[0039] To perform onboard picking, at least one storage and retrieval device may be equipped with an onboard robotic picking device that can be used to pick items from a loading unit without leaving the rack. The robotic picking device may include a vision system that identifies the item and enables directional control of the gripping device of the robotic picking device.

[0040] The storage facility may also include flow racks on at least one storage rack level.

[0041] It is known to implement on-board power supply means such as rechargeable batteries or large-capacity capacitors. The storage and retrieval devices can be charged while ascending if at least one of the vertical rails includes a power charging line adapted to connect to the power charging take-up of the storage and retrieval devices to charge the on-board batteries or capacitors of the storage and retrieval devices. These can also be charged using on-board regenerative devices connected to the lifting wheels to recover energy during descent.

[0042] The storage facility according to the invention may further comprise a removable maintenance platform adapted to be put into position to access the area between the vertical lifting rails, thereby allowing access to the storage levels as required, even in the area of ​​the vertical lifting rails.

[0043] Additionally, the storage facility of the present invention may include triple-tiered storage racks that reduce racking costs by 25% and increase storage density by 25%. It may also utilize stackable loading units that reduce racking costs by 25% and increase density by 25%.

[0044] A beneficial application of the present invention is in the field of vertical farming, where bins are used to store live plants (https: / / en.wikipedia.org / wiki / Vertical_farming).

[0045] The storage and retrieval device can store and retrieve containers containing plants. These special containers (e.g., totes) in such embodiments may be equipped with insert frames containing plant soil or other materials. Therefore, the storage and retrieval device is advantageously implemented in a way that protects it from splashes of water.

[0046] Such embodiments may additionally include modular, mobile plant treatment systems for value-added services (irrigation, pest control, fertilizer application, etc.).

[0047] These modular, mobile plant treatment systems include spray heads and pump-operated supply tanks, allowing for direct micro-dosing and allowing irrigation heads to be moved to reach only individual plants, minimizing water usage. Such tanks can be filled manually or automatically at the bottom level, i.e., with a dedicated refill station implemented instead of or in addition to a GTP station.

[0048] It is possible to operate a storage and recovery device loaded with plants and a storage and recovery device equipped with a modular mobile plant treatment system.

[0049] Further features and details of the present invention will become apparent from the following description of the drawings. FIG. 1 shows a schematic perspective view of a storage rack according to a first embodiment of the present invention. 2A-D show details of the shuttle of FIG. Figures 3A and 3B show details of the vertical lift rails within the rack. 4A and 4B show an alternative implementation of FIG. 5A-E show details of the change in direction of movement. FIG. 6 shows a schematic implementation of a shuttle with a "wedge arm." Figures 7-13 show different rack configurations for use with the present invention. FIG. 14 shows a possible configuration of storage with two storage areas connected by a shuttle bridge. Figure 15 shows a possible storage configuration using staggered height racks. 16A-E show an embodiment using AMRs for shuttle movement between aisles and ground transport between virtual GTP stations and storage racks. FIG. 17 shows an embodiment using a conventional conveyor and physical GTP station for container transport. 18A and 18B show an embodiment using a flow rack. Figure 19 shows the shuttle rescue operation. FIG. 20 shows an embodiment with a transport shuttle and a robotic picking shuttle, and with cross-aisle running rails forming a bridge. FIG. 21 shows an implementation of a removable maintenance platform. 22-24 show an embodiment of the use of the present invention in the context of vertical farming. 1 to 3 show a storage facility 1 having a plurality of storage racks R and storage rack levels 3 for storing loading units T, the storage racks R being arranged with aisles 2 between them on one side and back to back on the other side.

[0050] A loading unit T may be a tray, tote, container, etc., and is of storage type S in which products are stored for retrieval in fulfilling an order. A loading unit T may also be of order type O in which products are placed or placed in accordance with an order to at least partially fulfill the order.

[0051] Each storage rack level is provided on the opposite face of the storage rack R with running rails 4 on which at least one storage and retrieval device 5 can move along the length of the aisle 2 .

[0052] In this embodiment, the payload units T are stored in a storage rack R in a dual depth configuration.

[0053] The storage rack has load rails 1 (or mounts) on which the load units T rest, supported between a running rail 4 on one side and a longitudinal support rail 12 on the other side. The mounts 11 are arranged perpendicular to the longitudinal extension of the rack R (or aisle 2). Two (or more) mounts 11 support each load unit T (e.g., tray) from below. Mounts 11 are arranged along the storage space of each rack R and on level 3.

[0054] The running rails 4 and the longitudinal support rails 12 are attached to posts 13. The posts 13 face the aisle 2 or are arranged between the racks R arranged back to back.

[0055] Maintenance platforms 14 are located in the aisles 2 every fifth floor to allow maintenance personnel access to aisles, racks, shuttles, etc. as needed.

[0056] In this embodiment, the storage and retrieval device 5 is a so-called shuttle 5 having a transport area 6 for transporting at least one load unit T, which is arranged between the luggage handling means 7 and can extend into the storage rack R in a direction perpendicular to the length of the aisle 2 in order to transfer the load unit T to and from the storage rack R.

[0057] The parcel handling means 7 includes extendable telescopic rails 8 on both sides of the conveying area 6 and is provided with contact elements 9 that are pivotable between an upright non-use position and a horizontal use position, the contact elements 9 contacting the surface of the loading units T when they are pushed into or pulled out of the rack R or placed on the conveying area 6 in a known manner.

[0058] Each shuttle 5 has a first set of four travelling wheels 10 for horizontal movement along running rails 4 along each storage rack level 3 of the aisle 2. There are two wheels per set on each side of the storage and retrieval device 5, one or both on each side being motor driven via an articulated drive shaft.

[0059] Each aisle 2 has at least two pairs of vertical lifting rails 15 (sets of vertical lifting rails) on opposite sides of the storage racks R adjacent to each aisle 2. These are preferably located at the ends of the aisle. They are implemented as support posts. The vertical lifting rails 15 may also be attached to support posts 13 at appropriate locations.

[0060] Each shuttle 5 has lifting means 16 for engaging therewith to move vertically along the vertical lifting rail 15 .

[0061] The lifting means 16 of each shuttle 5 includes a set of four lifting wheels 16 that interact with vertical lifting rails 15. The four lifting wheels 16 have a vertical axis of movement compared to the four traveling wheels 10. The four lifting wheels 16 are retractable between an extended, engaged position (see FIG. 2C) for interacting with the vertical lifting rails 15 and a retracted, non-engaged position (see FIG. 2B) while moving horizontally along the running rails 4 along the respective storage rack level 3.

[0062] The lifting wheels 16 are positioned in the same positions as the moving wheels 10 on the shuttle 5 so as not to change the center of gravity, etc. As shown in Figure 2, the lifting wheels 16 are positioned slightly above the moving wheels so as not to interfere with horizontal movement or the center of gravity.

[0063] In this embodiment, the lifting wheels 16 are gears (pinions) and the vertical lifting rails 15 have corresponding straight gears (racks) or chains.

[0064] The retraction mechanism is preferably a lever arm 20 (see, e.g., FIG. 6 ) that is articulated so that the weight of the shuttle 5 presses the lifting wheels 16 against the linear gears or lifting rails 15, driving the lifting wheel set like a transport wheel, thereby allowing positive interaction and lifting. To do this, the retraction mechanism connects the lifting wheels 16 to the drive motor of the transport wheels 10 when in the extended position.

[0065] As shown schematically in FIG. 6, the lever arm 20 of the retraction mechanism is preferably hinged to provide a self-locking principle for the shuttle 5 under its own weight. This mechanism prevents uncontrolled vertical movement and collisions of the shuttle 5 in the event of a power failure. The lifting wheels 16 are attached to the frame of the shuttle 5 by the lever arm 20, with the hinge positioned higher than the lifting wheels 16, providing a wedge-like function. This allows the shuttle 5 to move slowly and passively downward. Additionally or alternatively, the lifting wheels 16 may be equipped with a mechanical fail-safe brake that can be activated to bring the shuttle 5 to a complete stop.

[0066] This mechanism allows the shuttle 5 to move up and down the vertical lift rail 15 as shown in Figure 3A.

[0067] Also, as shown in FIG. 3A, the horizontal running rails 4 must be interrupted by gaps or spaces 19 on either side of the direction change rails 17 that coincide with the vertical lifting rails 15 so that the shuttles 5 can access each level 3.

[0068] Each shuttle 5 has a second set of four retractable transport wheels 18 for moving horizontally along the storage rack level 3 of each aisle 2 and along direction change rails 17 in the area of ​​the vertical lift rails 15. The clearance or gap 19 is wide enough for the transport wheels 10 to "pass through".

[0069] Each shuttle 5 has a set of two retractable transport wheels 18 on each side, one or both of which are driven by articulated drive shafts and are used to change the direction of travel of the shuttle 5 from vertical to horizontal. The retractable transport wheels 18 are therefore positioned inboard and below the "normal" transport wheels 10.

[0070] Similar to the lifting wheels 16, the four retractable transport wheels 18 are retractable wheels that are controlled to be extended while the shuttle 5 moves along the direction change rail 17. In the extended position, the transport wheels 18 are coupled with the drive devices of the transport wheels 10.

[0071] In general, this allows for the following movements: As shown in Figure 2B, shuttle 5 uses travel wheels 10 to move horizontally along running rails 4 at each level 3 of each aisle 2. For vertical movement, as shown in Figure 2D, shuttle 5 uses lift wheels 16 to move vertically along lift rails 15 to move to each level. During direction change phases, as shown in Figure 2D, shuttle 5 uses travel wheels 18 to move along direction change rails 17.

[0072] Figures 5A-E show this operation in detail. First, the shuttle 5 contacts the vertical lift rail 15 with its driving climbing gear wheel 16, allowing it to move up and down to each level 3 (Figure 5A). Next, the four travel wheels 18 are extended from their retracted positions to their extended positions and connected to the direction change rail 17 (see Figure 5B). Next, the lift gear wheels 16 are retracted, and the shuttle 5 moves horizontally along the direction change rail 17 using the "second" auxiliary running wheels 18 (see Figure 5C). These connect to the inner flanges of rails 4 and 17, both of which have the same C-shaped cross section and are aligned. Once the gap 19 is crossed, the travel wheels 10 are positioned further away and connected to the upper flange of the running rail 4, allowing the shuttle 5 to travel along the running rail 4 simultaneously with the auxiliary running wheels 18. That is, the shuttle 5 is assisted by either the travel wheels 10 on the upper flange forming the running rail 4 or the auxiliary running wheels 18 on the lower inner flange forming the direction change rail 17 (see Figure 5D). Further movement causes the shuttle to leave the area of ​​the lifting rail 15 and move using the travelling wheels 10, only connected to the running rail 4 (see FIG. 5E). The auxiliary running wheels 18 can then be retracted.

[0073] The retraction mechanism can be implemented in various ways: the movement of the auxiliary travelling wheels 18 into position can be implemented by a pneumatic cylinder mechanism, a rack and pinion mechanism or a drive lever linkage mechanism, or a servo motor drive can also be implemented.

[0074] Alternatively, the auxiliary running wheels 18 can be moved horizontally to be positioned in a vertical line directly below (or above) the traveling wheels 10, allowing the shuttle 5 to benefit from the gap 19 as it moves vertically. After reaching the destination level, the auxiliary running wheels 18 can be moved horizontally to be positioned in a connected position.

[0075] As shown in Figures 4A and 4B, it is possible to implement multiple sets of lift rails 15 for each aisle 2. In the embodiment shown, there are two sets of lift rails 15A, B adjacent to each other within the aisle.

[0076] This allows for the use of an upstream-only set and a downstream-only set, increasing throughput. It is clear that there is another pair of two sets at the other end of the corridor, as indicated by the arrows.

[0077] This allows for the shuttle 5 to be circumvented by using the other set of lifting rails 15 (shown by the dashed lines) even if it gets stuck on one set.

[0078] Figures 7-15 show various possible implementations of racks and storage. In Figure 7, the rack allows for single-deep storage of load units T (totes or containers), while Figure 8 implements double-deep storage of load units T. Figure 9 shows load units T stacked in double-deep storage. Figure 10 shows a triple-deep storage implementation of load units T, which are stacked in Figure 11. As shown in Figure 12, load units T are trays and are shown in triple-deep storage. It is also possible to place or store load units T directly without using trays, totes, etc., as shown in Figure 13.

[0079] To handle stacked load units T, the corresponding shuttle 5 may be equipped with a mechanism for gripping the side walls with a certain pressure and lifting them, or a mechanism for gripping them from the side and lifting the load units. Such mechanisms allow the load units to be stacked or unstacked without leaving the aisle.

[0080] Figures 14 and 15 show different implementations of the storage itself.

[0081] In Figure 14, two storage areas (smaller area 1A and larger area 1B) are connected by a raised shuttle bridge 22 (by extending the running rails 4), which connects the aisles 2 of both areas 1A, B and allows the movement of shuttles 5 between areas 1A, B. This allows floor-based movement below the bridge 22.

[0082] In FIG. 15, the rack R has three different heights 23A, B, C along the extension of the aisle 2, so that the storage 1 can be placed on the slope of a hill, for example.

[0083] Figures 16-17 show various implementations of storage facilities related to order fulfillment.

[0084] 16A-E illustrate an embodiment in which an AMR 24 is used to transfer shuttles 5 between aisles 2 and / or for ground transport of payload units T between virtual GTP stations 25 and storage racks R.

[0085] In Figure 16A, the shuttle 5 is lowered from the bottom tier 3 of aisle 2 onto a discharge conveyor 26 located in the extension of the aisle on one side of rack R. A corresponding storage conveyor 27 is located on the opposite side. The shuttle 5 can therefore discharge the load unit T onto the discharge conveyor 26 or retrieve the load unit T from the storage conveyor 27 . The conveyors 26, 27 are supplied or serviced by a ground-based AMR 24 that includes a transport platform for the payload unit T. The AMRs 24 shuttle between conveyors 26, 27 and a virtual GTP station 25 formed on the fly by the AMRs 24 carrying loading units T, which can be either order loading units (to be picked) or product loading units (to be picked) in the area where the pickers P are located, which can be a fixed or variable area. Additionally, the AMR24 exchanges loading units T between aisles.

[0086] In the alternative version of Figures 16B-E, shuttle 5 can also leave aisle 2 and change aisles 2 using a second version of AMR 28 with a carrying platform 29 for shuttle 5. To change aisles 2, AMR 28 enters the respective aisle and positions itself under lift rail 15 (see Figure 16C). Shuttle 5 then descends onto platform 29 and retracts lift wheels 16 (Figure 5D). AMR 28 then carries shuttle 5 away from aisle 2 and travels to its destination, which could be a service and maintenance station.

[0087] FIG. 17 shows a similar embodiment to FIG. 16 a, but using a conventional conveyor 30 for transporting payload units T to the front zone and physical GTP station 31 .

[0088] Direct horizontal exchange of loaded units T is effected from one aisle 2 to the adjacent aisle 2' via exchange locations Q in the storage rack R, with the shuttle 5 itself using its telescopic arms to actively move the units T horizontally within exchange location Q.

[0089] In addition to the lifting shuttle 5, the storage facility 1 shown in FIG. 17 is also provided with a lift 32 that is provided in at least one storage rack for each aisle 2 and that can speed up vertical transportation.

[0090] The lift 32 connects to the pre-zone conveyor 30 via a discharge conveyor 33 and a storage conveyor 34. The lift 32 has a liftable conveyor platform 35 which connects to buffer conveyors 36 at each level.

[0091] 18A-B show an embodiment using flow racks as GTPs 37 along the outer length of each storage location. Shuttles 5 can feed loads from the aisles 2 behind the flow racks by pushing load units through, similar to the operation of exchange location Q described above. The GTP 37 has presentation space for two diagonal rows 38, served by flow racks and positioned on top of each other. Beneath them is a discharge conveyor 39 for transporting picked load units to the packaging area.

[0092] As shown by the arrows, the flow of material is "circular", with upward movement using the lift rails 15 on one side of the store or aisle 2, downward movement using the lift rails 15 on the other side of the store or aisle 2, and movement from the upward to the downward lift rails using the upper level 3 and movement in the opposite direction using the lower level.

[0093] Figure 19 shows the rescue of a shuttle 5B that has broken down somewhere on the running rail 4 of the aisle 2. The shuttle 5B is rescued by a controllable second shuttle 5A, which then pushes it to the end of the aisle 2, making it more easily accessible.

[0094] To that end, shuttle 5A includes a set of bumpers 40 facing in the direction of travel along path 2 and contacting surfaces 41 of the front and rear housings of each of shuttle 5B, or alternatively a pair of bumpers 40 on each of the second shuttle 5B, to allow for a pushing operation.

[0095] Bumpers 40 may be located on the surface 41 of the front housing of each of the shuttles 5A, B or on the lift wheels 16', depending on the arrangement.

[0096] FIG. 20 shows an embodiment with a shuttle 5 (same as above) and a robotic picking shuttle 42, and also with cross-aisle running rails 43 for movement of the shuttle 5 between aisles 2, forming a bridge perpendicular to the direction of the aisles 2 and propelled by a set of lifting wheels 16.

[0097] The robotic picking shuttle 42 has all the functions of the climbing shuttle 5 and additionally has a robotic picking device 44 and a vision system 45 for identifying each item to be picked. The robotic picking shuttle 42 carries the order loading unit that it has picked using the robotic picking device 44 and vision system 45 without leaving the rack R. The product loading unit is presented to the aisle by the climbing shuttle 5.

[0098] Figure 21 shows an implementation of a removable maintenance platform 14 (Figure 21A) adapted to be put into position to access the area between the vertical lifting rails 15. Obviously, this area is not always accessible with a fixed maintenance platform.

[0099] There are two options for the maintenance platform 14. Both have an extendable lattice-based platform 14A that can be extended or retracted by means of a telescoping platform 14B that can slide or rotate for extension and retraction (see FIG. 21B), providing expanded access to the area between the vertical lift rails 15.

[0100] Figures 22-24 show an embodiment of the use of the invention in the context of vertical farming. In this context, the storage is similar to that of Figure 16A, except that the loading units are special trays 46 carrying plants (see Figures 23A, B, C) and the shuttle 4 carries a special plant maintenance loading unit 47.

[0101] Rack R supports trays 46 similar to a normal loading unit T and is equipped with a light source and the like for growing plants. Trays 46 can hold either a box-shaped open insert 46A for directly holding soil or growing medium, an insert 46B with openings 48A arranged in a grid for holding flower pots 48B, or a compartmented insert 46C with multiple compartments for directly holding plants.

[0102] As shown in detail in Figure 24, a special plant maintenance load unit 47 may be transported on a tray 46. The plant maintenance load unit 47 includes a water tank 47A, a pump 47B, two water dispensers 47C (one on each side of the aisle to water the plants on both sides), an electrical energy source 47D (battery, capacitor, etc.), a controller 47E, etc. The water dispenser 47C may be mounted adjustably like a robotic arm.

[0103] In this manner, the shuttle 5 can transport the plant maintenance load unit 47 through the rack R to spray water on the plants. The water may contain fertilizers, pesticides, etc. The shuttle 5 can also move, eject or store trays 46 containing plants as needed.

[0104] In all embodiments, at least one of the vertical rails 15 may include a power charging line adapted to connect to a power charging take-up of the shuttle 5 to charge on-board batteries or capacitors. Additionally, the shuttle 5 may include a regenerative device connected to the lift wheels to recover energy during descent.

Claims

1. A storage facility (1) having a plurality of storage racks (R) and a storage rack level (3) for storing load units (T), wherein two storage racks (R) have an aisle (2) between them; each storage rack level having running rails on opposite sides of said storage rack (R) on which at least one storage and retrieval device (5) can move the length of said aisle (2); In each aisle (2), at least two pairs of vertical lifting rails (15) are provided on the opposing surfaces of the storage racks (R) adjacent to each corresponding aisle (2); the storage and retrieval device (5) is arranged between load handling means that can extend into the storage racks (R) in a direction perpendicular to the length of the aisles (2) and has a handling area for at least one load unit (T) for placing or retrieving the load unit (T) into or from the storage racks (R); each storage and retrieval device (5) having a first set of four moving wheels for moving along said running rails arranged horizontally along each corresponding storage rack level (3) of the aisle (2), two wheels per set on each side of said storage and retrieval device (5), one or both of which on each side are driven on an articulated drive shaft; A storage facility characterized in that each storage and retrieval device (5) has lifting means for vertical movement, in particular along said vertical lifting rails.

2. 2. The storage facility (1) according to claim 1, characterized in that the lifting means of each storage and retrieval device (5) comprises a set of four lifting wheels (16) for interaction with the vertical lifting rails (15), the four lifting wheels (16) having a vertical axis of movement compared to the four moving wheels, the four lifting wheels (16) being retractable between an extended, engaged position for interaction with the vertical lifting rails and a retracted, non-engaged position when moving horizontally along the running rails provided horizontally along the respective storage rack level (3).

3. 3. A storage facility (1) according to claim 1 or 2, characterized in that each storage and retrieval device (5) has a second set of four, preferably retractable, moving wheels for movement along direction-changing rails arranged horizontally along each respective storage rack level (3) of the aisle (2) in the region of the vertical rails, with two wheels per set on each side of the storage and retrieval device (5), one or both of which are driven on an articulated drive shaft and are used to change the direction of movement of the storage and retrieval device (5) from vertical movement along the vertical lifting rails to horizontal movement along the running rails of each respective storage rack level (3) of the aisle (2).

4. 4. The storage facility (1) according to claim 3, characterized in that the four moving wheels for moving along direction change rails arranged horizontally along the respective storage rack levels (3) of the aisles (2) in the region of the vertical rails are retractable wheels and are controlled so as to be extended while the storage and retrieval device (5) moves along the direction change rails.

5. 5. The storage facility (1) according to claim 1, wherein the direction change rails are arranged between the vertical lifting rails of each level (3) having running rails, and the running rails of each corresponding storage rack level (3) of an aisle (2) have a gap in the region of the respective vertical rails relative to the direction change rails arranged horizontally along the respective corresponding storage rack level (3) of the aisle (2).

6. 6. A storage facility (1) according to any one of claims 1 to 5, characterized in that the cross-aisle running rails form a bridge perpendicular to the aisle direction for the movement of the respective storage and retrieval devices (5) between the aisles (2), preferably propelled by said set of four lifting wheels.

7. 7. The storage facility (1) according to any one of claims 1 to 6, characterized in that the lifting wheels are gear wheels (pinions) and the vertical rails and / or cross-aisle running rails have corresponding straight gears (racks) or chains.

8. 8. A storage facility (1) according to any one of claims 1 to 7, characterized in that a direct horizontal exchange of loading units (T) from one aisle (2) to an adjacent aisle (2') takes place via an exchange location (Q) in the storage rack (R), and the storage and retrieval device (5) itself actively moves the transport units (T) horizontally in the exchange location (Q) using the load handling means, preferably telescopic arms with interlockable load contact means.

9. 9. A storage facility (1) according to any one of claims 1 to 8, characterized in that the racks have interfaces to conveyors in the pre-zone or front zone of the working area for connection to picking stations located anywhere between the lowest and highest levels, preferably at least one per aisle.

10. 10. The storage facility (1) according to any of the preceding claims, characterized in that the storage racks have at least one interface allowing the transfer of load units to an autonomous mobile robot (AMR) for further ground transport.

11. Storage facility (1) according to any of claims 1 to 10, characterized in that said facility comprises a ground transport AMR implemented to enable the transport of storage and retrieval devices (5) within said storage rooms, preferably between aisles (2).

12. A storage facility (1) according to any of claims 1 to 11, characterized in that said facility comprises a storage and retrieval device (5) implementing stacking means for stacking and unloading loading units, preferably containers or packing boxes, one on top of the other on its handling area.

13. 13. Storage facility (1) according to any of the preceding claims, characterized in that there is a lift for at least one storage rack per aisle (2).

14. 14. A storage facility (1) according to any one of claims 1 to 13, characterized in that more than one storage and retrieval device (5) can be guided towards one level.

15. 15. A storage facility (1) according to any one of claims 1 to 14, characterized in that the storage and retrieval device (5) comprises a set of bumpers facing the direction of movement along the aisle for contacting a corresponding pair of bumpers of each of the second storage and retrieval devices (5) to enable a pushing action.

16. 16. A storage facility (1) according to any of claims 2 to 15, characterized in that the mechanism for retracting the lifting wheels (16) comprises a self-locking principle, in particular by means of lever arms (20) that articulate to allow positive interaction and lifting, whereby the lifting wheels (16) are pressed towards the lifting rails (15) by the weight of the storage and retrieval device (5) and the set of lifting wheels is driven as if it were a moving wheel.

17. 17. Storage facility (1) according to claim 16, characterized in that the lever arm (20) of the storage mechanism is preferably hinged and driven so as to stop the storage and retrieval device (5) in case of a (power-related) failure due to uncontrolled vertical movement or a collision, and optionally the lifting wheels (16) are attached by lever arms (20) to the frame of the storage and retrieval device (5) so as to perform a wedge-like function.

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