Joint Assembly

Abstract

1. A connecting block (2) comprising: i) a socket (6) for receiving a connecting end of a connecting element along a first axis XX, the socket having an inner wall (10); ii) a plurality of fingers (24) resiliently biased to extend substantially radially inward from the inner wall (10) of the socket (6) to align with the connecting end of the connecting element when received in the socket in use, the plurality of fingers being spatially dispersed around the inner wall of the socket to define a guide for guiding the connecting end of the connecting element toward a center of the socket; and iii) an inlet (40) comprising an inlet lumen (42) extending along a second axis YY from an opening (44) in the exterior of the connecting block to an opening (46) in the inner wall of the socket, for injecting adhesive into the socket.

Description

[Technical Field]

[0001] The present invention relates to the field of joints between connecting blocks and connecting elements, and more particularly to joints between a connecting element and a socket of a connecting block into which the connecting element mates. [Background technology]

[0002] With the increasing use of lightweight materials with high strength-to-weight ratios, such as carbon fiber or composites, in the construction of various load-handling structures or frames, there is also a growing need for improved bonding between the various components of the structure or frame. Fabricating such structures or frames involves assembling multiple connection elements into a desired shape and / or size. Connecting the connection elements requires a joint between a connection block or connector and the connection element, e.g., a tube or rod, typically requiring a connection block having a socket into which the tube or rod is inserted. To couple the tube or rod to the connection block, it is desirable to secure the tube or rod to the connection block using an adhesive or glue. A layer of adhesive is applied to the exterior surface of the connection end of the tube or rod before the connection end is inserted into the socket of the connection block. Similarly, or in addition, the interior wall of the socket can be coated with a layer of adhesive, and the connection end of the tube or rod is then inserted into the socket. Any excess glue or adhesive that escapes from the socket is then wiped clean. The tube or rod and connection block are then held securely in the desired position, typically by a jig, until the adhesive cures. The duration of the connection block and the connection element is very much dependent on the setting time of the glue or adhesive.

[0003] However, a problem with this technique for bonding connecting blocks to tubes or rods is the lack of control over the amount of adhesive that can be applied around the connecting ends of the tubes or rods before the tubes or rods are inserted into the sockets of the connecting block. This lack of control can result in insufficient adhesive coverage of the connecting ends of the tubes or rods before they are inserted into the sockets, resulting in insufficient adhesion between the connecting block and the connecting element. If the adhesive is allowed to cure for too long, the adhesive tends to pool at the bottom of the socket depending on the orientation of the socket before curing. In some cases, some of the adhesive may escape from the socket before it has a chance to cure. This can result in inconsistent coverage of the connecting ends of the rods or tubes, which can result in insufficient adhesive coverage on the connecting ends of the tubes or rods and poor adhesion between the connecting block and the tubes or rods. When a frame or structure is a load-carrying structure comprising multiple assembled connecting blocks and tubes or rods, such inconsistent adhesion between the various components of the frame can create weak areas in the frame structure, especially around the areas of the joints between the sensitive connecting blocks and the connecting elements.

[0004] Therefore, there is a need for a connection block that does not suffer from the above problems. Summary of the Invention

[0005] The present invention alleviates the above problems by providing a connecting block with a socket having features that allow the adhesive to flow around the connecting end of the connecting element to bond the connecting element to the connecting block while at least partially confining the adhesive within the socket. This increases the amount of time the adhesive remains within the socket before hardening, increasing adhesive coverage on the connecting element and thereby increasing the bond between the connecting element and the connecting block. More particularly, the present invention provides a connecting block comprising: i) a socket for receiving a connecting end of a connecting element along a first axis, the socket having an inner wall; ii) a plurality of fingers resiliently biased to extend substantially radially inwardly from an inner wall of the socket so as to follow the connecting end of the connecting element when the connecting end is received in the socket in use, the plurality of fingers being spatially distributed around the inner wall of the socket so as to define a guide for guiding the connecting end of the connecting element towards a center of the socket; iii) an inlet having an inlet lumen extending along a second axis from an opening in the exterior of the connecting block to an opening in the interior wall of the socket for injecting adhesive into the socket; A connection block is provided, comprising:

[0006] In the present invention, the connecting element can be a tube, rod, or pipe shaped to fit into a socket of the connecting block. The socket can be a blind hole or, optionally, a through hole. In one example, the connecting block can include a plurality of sockets, the first axes of each of the plurality of sockets forming an acute or obtuse angle with each other. Optionally, the angle is between 45° and 135°. Optionally, the angle is substantially 90°, such that the first axes of each of the plurality of sockets are perpendicular to each other. Optionally, the first axes of each of the plurality of sockets intersect. In the present invention, the term "intersect" is interpreted to cover any angle between the first axes of each of the plurality of sockets.

[0007] The cross-sectional diameter of the socket is slightly larger than the cross-sectional diameter of the connecting element to allow the connecting end of the connecting element to be inserted into the socket. The fingers are resiliently biased to extend radially inward from the inner wall of the socket, allowing adhesive injected into the socket to be at least partially contained within the socket, thereby preventing too much adhesive from escaping the socket, but also allowing adhesive to flow between the resiliently biased fingers to reach areas of the socket beyond the resiliently biased fingers. The present invention further provides an inlet comprising an inlet lumen extending along a second axis from an opening on the exterior of the connecting block to an opening in the inner wall of the socket for injecting adhesive into the socket. Preferably, the inner wall of the socket comprises a sidewall, and the inlet lumen extends from the opening on the exterior of the connecting block to an opening in the sidewall of the socket. Optionally, the first axis and the second axis form an acute or obtuse angle for injecting adhesive into the socket from the inlet. For example, the angle between the first axis and the second axis can range from 35° to 135°. Optionally, the first axis is substantially perpendicular to the second axis. This option provides the most direct path from the inlet into the socket. Optionally, the first axis is substantially perpendicular to the second axis. Optionally, the first axis intersects with the second axis.

[0008] The fingers act as a barrier to at least partially trap the adhesive within the socket for a sufficient length of time to prevent too much adhesive from escaping the socket before curing. To allow the fingers to conform to the connecting end of the connecting element, the fingers are optionally spaced around the inner wall of the socket, thereby deforming one or more of the fingers when the connecting end of the connecting element is inserted into the socket. The spacing between the fingers controls the level of adhesive trapping within the socket. Optionally, the spacing between adjacent fingers ranges from 0.1 mm to 1 mm. The separation between the fingers depends on the viscosity of the adhesive. For adhesives with relatively high viscosity, the separation can preferably be greater than for adhesives with relatively low viscosity. The separation between the fingers can be tailored to the viscosity of the adhesive to control the amount of adhesive that can be trapped within the socket before curing.

[0009] To maximize the level of adhesive coverage on the connecting end of the connecting element, it is necessary for any air that builds up upstream of the adhesive to be fully released before the adhesive cures; otherwise, air trapped in the socket or in front of the adhesive would prevent a sufficient supply of adhesive from being injected into the socket. The fingers must not only be able to release air upstream of the adhesive, but also at least trap the adhesive in the socket for a sufficient length of time to prevent too much adhesive from escaping the socket before curing. When the fingers are discrete, elongated fingers, the spacing between adjacent fingers may be too small to allow air to pass between them. The spacing or gap between the fingers may close when the connecting end of a connecting element, such as a tube or rod, is inserted into the socket, to the extent that air may be trapped in the socket. This prevents the adhesive from fully covering the connecting end of the connecting element when injected into the socket's inlet. To control the flow of adhesive around the connecting end of the connecting element while providing a passage for air to vent, the fingers optionally include a plurality of fins arranged so that each fin at least partially overlaps an adjacent fin. The at least partially overlapping fins can control glue flow around the connecting end of the connecting element while providing a passageway for ventilation. Because the multiple fins are discrete, the spacing between adjacent fins at the root or foot of the fins, which connects to the inner wall of the socket, is such that when the fins close to overlap each other around the connecting end of the connecting element, the passageway between adjacent fins at the root remains open. In the present invention, the multiple fins close when adjacent fins are in contact. Because the multiple fins are arranged so that adjacent fins at least partially overlap, the multiple fins close when at least a portion of the overlapping areas of the fins come into contact. The passageway is large enough to allow ventilation, yet provides sufficient resistance to ensure that the adhesive fills the gap between the connecting end of the connecting element and the inner wall of the socket.An example of a shape of fins that can be arranged such that each fin at least partially overlaps an adjacent fin is a blade. The blades can be square or triangular. When the blades are triangular, the fins are arranged in a turbofan configuration.

[0010] Another feature of the present invention is that the plurality of fingers are spatially dispersed around the inner wall of the socket to define a guide for guiding the connecting end of the connecting element toward the center of the socket. When guided by the plurality of fingers, the connecting element can be repositioned within the socket due to the resilience of the plurality of fingers. In any case, the longitudinal axis of the connecting element, defined by the first axis, forms an acute or obtuse angle with the second axis of the inlet lumen. When the connecting element is guided along the first axis of the socket, the second axis of the inlet is substantially perpendicular to the first axis. Optionally, the plurality of fingers are arranged around the peripheral wall or periphery of the inner wall of the socket to surround the connecting end of the connecting element when inserted into the socket. Preferably, the plurality of fingers extend from the inner wall of the socket to form an opening concentric with the opening or mouth of the socket, allowing the connecting end of the connecting element to be guided toward the center of the socket. Optionally, each of the plurality of fingers is inclined relative to the inner wall of the socket at an angle ranging from 5° to 90°. Preferably, the angle is an acute angle. The plurality of fingers are arranged circumferentially around the inner wall of the socket to form a frusto-conical shape having an opening concentric with the opening or mouth of the socket.

[0011] To allow the fingers to move within the socket, optionally, each of the fingers has a first end hinged to the inner wall of the socket by a flexible joint and a second end, the second end being a free end. Because stress is concentrated at the joint where each of the fingers is hinged to the inner wall of the socket at the first end, there is a risk that fatigue will occur in one or more of the fingers, which may eventually cause one or more of the fingers to detach from the inner wall of the socket. To reduce fatigue at the joint where each of the fingers is hinged to the inner wall of the socket, optionally, the inner wall includes a recess adjacent the first end of each of the fingers to allow each of the fingers to rotate about the first end. This recess distributes stress over a larger area rather than concentrating it at a single point on the inner wall of the socket, thereby reducing stress at the joint between each of the fingers and the inner wall of the socket. Where the plurality of fingers comprises a plurality of fins, the shape of each of the plurality of fins may be such that a first end of the fin has a width greater than a second end, e.g., triangular, to allow the plurality of fins to at least partially overlap adjacent fins.

[0012] A second end or tip of each of the plurality of fingers is a free end and is arranged to contact a connecting end of the connecting element when the connecting element is inserted into the socket. The second ends of the plurality of fingers are arranged to form an opening in the socket that is concentric with the opening of the socket. Optionally, the second end comprises a tapered end or has a tapered surface to help guide the connecting end of the connecting element when the connecting element is inserted into the socket.

[0013] The resilience of the fingers allows the connecting element to move within the socket when inserted into the socket of the connecting block. This provides a level of flexure or adjustment room for the connecting element relative to the connecting block when assembled. Optionally, at least a portion of each of the fingers is constructed of a compliant material to allow elastic deformation of one or more of the fingers when a force is applied to one or more of the fingers. Examples of compliant materials include, but are not limited to, elastomeric materials, such as plastic materials. The movement of the connecting element within the socket of the connecting block is particularly important when a level of variation exists between similar parts, making it impossible to reproduce two connecting blocks with the exact same shape and / or size. This is especially true when the connecting block provides one or more functional features of a structure, such as mounting a wheel or motor. Such variations are inherent in the manufacturing process of the connecting block. These include various molding processes for the connecting block, including, but not limited to, additive manufacturing, injection molding, casting, or other molding techniques known in the art. Although rigorous quality control procedures are implemented to ensure the repeatability of connecting blocks, some variation in the exact shape and / or size of connecting blocks may still occur. Such differences between the dimensions and / or shapes of similar connecting blocks are reflected when the connecting blocks are assembled with connecting elements to form a frame or structure having a predetermined tolerance for size and / or shape. Without the ability to allow some flexure or movement to the connecting elements within the sockets of the connecting blocks, there is a risk that the assembled frame or structure may not meet the predetermined tolerance for size and / or shape of the frame. If the frame or structure forms part of a larger structure or frame, i.e., is a subframe, such differences in shape and / or size of connecting blocks as a result of the forming process may be amplified when the subframe is assembled to form the frame.To ensure that the assembled frame or subframe meets the required tolerances when assembling the subframe, it is necessary that the stage of assembling the connecting blocks to the connecting elements allow adjustment of the connecting elements relative to the connecting blocks when inserted into the sockets and before injecting adhesive into the sockets. Having a plurality of resiliently biased fingers extending radially inward from the inner wall of the socket allows movement of the connecting elements within the socket, thereby allowing fine adjustment to be made between the connecting elements and the connecting blocks when predetermined tolerances in shape and / or size are required.

[0014] During the injection of adhesive into the socket through the inlet, the pressure of the fluid, e.g., air at the front or upstream side of the adhesive, gradually increases as the amount of adhesive increases within the socket. Without relief, this increase in pressure could prevent the adhesive from filling the socket. To relieve this pressure as adhesive is injected into the socket through the inlet, the connecting block optionally further includes an outlet port having an outlet lumen extending along a third axis from an opening in the inner wall of the socket to an outlet opening on the exterior of the connecting block for discharging the fluid from the socket. Like the second axis, the third axis forms an acute or obtuse angle with the first axis. Optionally, the third axis is substantially perpendicular to the first or second axis. This option provides the most direct path from the socket or glue channel into the outlet port. Optionally, the third axis can intersect with the first axis.

[0015] The pressure of the air at the head of the adhesive depends on the pressure applied to the adhesive as it is injected into the socket through the injection port. Therefore, the amount of adhesive needed to bond the connection element to the socket depends on several variables, including but not limited to: i) viscosity of the adhesive; ii) adhesive curing time; iii) the pressure applied when injecting the adhesive into the socket; iv) Increased pressure at the beginning of the adhesive in the socket Includes.

[0016] Observations have shown that low-viscosity or thin adhesives flow more easily than high-viscosity or thick adhesives. Because the outlet provides relief for this pressure buildup, adhesive emerging from the outlet can provide an indication that the adhesive has sufficiently filled the socket, and therefore, further injection of adhesive into the socket can then be stopped to avoid wasting adhesive and, more importantly, to prevent excess adhesive from dripping onto other areas of the frame or structure and / or components attached to the frame or structure. Consequently, the cross-sectional area of ​​the outlet lumen can affect the rate at which the adhesive fills the socket before curing. For a given applied injection pressure, a relatively large cross-sectional area of ​​the outlet lumen allows more fluid to escape through the outlet, thereby increasing the flow rate of adhesive within the socket. By definition, the "flow rate" of an adhesive is interpreted as meaning the volumetric flow rate of fluid in a socket or glue channel, i.e., Q = V / t, where V is the volume of fluid passing through a given cross-sectional area of ​​the socket, t is the time required to pass through that given cross-sectional area of ​​the socket, and Q is the volume of fluid passing through that given cross-sectional area of ​​the socket per unit time. As the connecting end of the connecting element occupies a portion of the socket's volume, the flow of adhesive within the socket can be directed into the empty space extending between the inner wall of the socket and the outer surface of the connecting element, also defined as the glue channel. For adhesives with relatively long curing times, excess adhesive may be lost through the outlet because more adhesive needs to be injected into the socket before the adhesive has time to cure. Conversely, if the cross-sectional area of ​​the outlet lumen is relatively small, the smaller cross-sectional area of ​​the outlet lumen will have the opposite effect, since the adhesive will have little time to fill the socket due to increased air pressure before it begins to cure. This is especially true if the adhesive has a relatively short cure time. Depending on the viscosity of the adhesive and its cure time, a trade-off must be made between the flow rate of the adhesive in the socket and the cross-sectional area of ​​the outlet lumen.Examples of types of adhesives that can be used to adhere the connecting elements to the sockets of the connecting block include, but are not limited to, adhesives that include acrylates, preferably methacrylates, and more preferably methyl methacrylate.

[0017] One way to affect the flow rate of adhesive within the socket is to control the cross-sectional area of ​​the outlet lumen. Optionally, the outlet lumen includes a first portion having a first cross-sectional area and a second portion having a second cross-sectional area, the second cross-sectional area being different from the first cross-sectional area such that the velocity of fluid through the first portion differs from the velocity of fluid through the second portion. The different cross-sectional areas of the outlet lumen affect the velocity of fluid, and therefore adhesive, through the outlet lumen, thereby limiting the fluid's escape through the outlet and thus affecting the flow rate of adhesive within the socket. To further limit adhesive escape through the outlet, optionally, the first cross-sectional area is smaller than the second cross-sectional area such that the velocity of fluid through the first portion is greater than that through the second portion. The smaller cross-sectional area of ​​the first portion of the outlet lumen limits the velocity of adhesive flow within the socket, while the larger cross-sectional area of ​​the second portion of the outlet lumen acts as a well, due to its larger volumetric capacity, to accommodate any excess adhesive that flows from the first portion. The larger cross-sectional area of ​​the second portion helps prevent adhesive from escaping through the exhaust openings on the exterior of the connecting block and contaminating other areas of the frame and / or components attached to the frame.

[0018] To increase the level of adhesive containment within the socket, optionally, the plurality of fingers comprises a first set of fingers and a second set of fingers, each of the first set of fingers and the second set of fingers comprising a plurality of fingers according to the present invention. Optionally, the first set of fingers are axially spaced apart from the second set of fingers along the longitudinal axis of the socket. Optionally, an inlet, more particularly an inlet opening in the inner wall of the socket, is disposed between the first set of fingers and the second set of fingers. The spacing between the first set of fingers and the second set of fingers defines a length of a glue channel that confines adhesive between the first set of fingers and the second set of fingers. This allows various sections or portions of the connecting element to be coated with adhesive before the adhesive hardens. Additionally, defining the length of the glue channel between the first and second sets of fingers prevents adhesive from reaching areas of the connecting element that have little effect on the bond strength between the connecting element and the connecting block, thereby reducing the amount of adhesive required to bond the connecting element to the connecting block. If the connecting element is hollow or tubular, reducing the amount of adhesive reaching the distal end of the tube limits the amount of adhesive that enters the hollow portion of the tube. The first and second sets of fingers not only confine the adhesive along various sections of the connecting element, but also provide additional support for the connecting end of the connecting element when inserted into the socket.

[0019] The fingers help confine the adhesive within the socket, but depending on the viscosity of the adhesive, separation between the fingers of the fingers can optionally allow the adhesive to flow between the fingers and reach areas of the socket behind the fingers. Optionally, the fingers are positioned between an inlet and an outlet to allow adhesive to flow along the connecting end of the connecting element and pass through the fingers when injected into the socket. Thus, adhesive injected into the socket through the inlet at one end of the socket is forced through the fingers and toward the outlet. The presence of adhesive flowing into the outlet can provide an indication that the adhesive has flowed through the fingers.

[0020] Optionally, the fingers can be integrally formed within the connecting block, for example, using additive manufacturing in the fabrication of the connecting block allows complex shapes with internal structures to be fabricated as a single, integral body.

[0021] The present invention provides a joint assembly comprising: i) a connection block according to the present invention; ii) a connecting element receivable in a socket of a connecting block; A joint assembly is provided, comprising:

[0022] Optionally, the connecting element comprises a tube or a rod.

[0023] An example of the assembly of connecting blocks according to the invention, which are bonded to connecting elements by adhesive to form a frame for supporting or mounting various components, is found in the creation of a robotic material handling device for lifting and moving one or more containers which can be stacked in an inbound and outbound system, the inbound and outbound system comprising a grid structure comprising a plurality of grid members, the grid members comprising a first set of grid members and a second set of grid members, the second set of grid members being substantially orthogonal to the first set of grid members such that the plurality of grid members are arranged in a grid pattern to guide movement of the robotic material handling device on the grid structure. Preferably, the present invention relates to a robotic material handling device for lifting and moving one or more containers which can be stacked in an inbound and outbound system, the inbound and outbound system comprising a grid structure comprising a plurality of grid members, the grid members comprising a first set of grid members and a second set of grid members, the second set of grid members being substantially orthogonal to the first set of grid members such that the plurality of grid members are arranged in a grid pattern to guide movement of the robotic material handling device on the grid structure, a) a container lifting mechanism comprising a container gripping assembly configured to releasably grip a container and a lifting drive mechanism configured to lift and lower the container gripping assembly; b) a wheel assembly comprising a first set of wheels engaging a first set of grid members to guide movement of the load handling device in a first direction and a second set of wheels engaging a second set of grid members to guide movement of the load handling device in a second direction, wherein the second direction is transverse to the first direction; c) a wheel positioning mechanism configured to selectively lower or raise the first set of wheels or the second set of wheels into engagement or disengagement with the first set of grid members or the second set of grid members; a frame or frame structure for supporting the A robotic load handling device is provided, wherein the frame comprises a plurality of modular subframes arranged in a vertical stack, at least one of the plurality of modular subframes comprising at least one connection block according to the present invention and a connection element received in a socket of the at least one connection block.

[0024] Optionally, the frame further supports a receptacle for accommodating a power source, the receptacle having an externally accessible open top end for receiving the power source in a substantially vertical direction, and comprising a charge-receiving element for electrically coupling with a charge-providing element of the power source to provide power to the wheel positioning mechanism and the container lifting mechanism.

[0025] Optionally, at least one of the plurality of modular subframes comprises at least four connection blocks, each of the at least four connection blocks of each modular subframe connected to two other connection blocks by a plurality of connection elements to form a rectangular modular subframe.

[0026] Optionally, each of the plurality of modular subframes comprises at least four connection blocks, each of the at least four connection blocks of each modular subframe connected to two other connection blocks by a plurality of connection elements to form a rectangular modular subframe, and the connection blocks of vertically adjacent modular subframes are connected by the connection elements.

[0027] Thus, a plurality of these rectangular modular subframes can be connected to one another in a vertical stack by one or more vertical connection elements to form a frame or frame structure. Various functions of the load handling device, such as the container lifting mechanism, wheel assembly, wheel positioning mechanism, and / or electrical components, are supported by the frame structure. The term "supported" is broadly interpreted to include physically supported by the frame structure, e.g., attached to and / or integrally formed with the frame structure. Optionally, at least one connection block comprises at least a portion of the container lifting mechanism, wheel assembly, wheel positioning mechanism, and / or electrical components. Optionally, at least a portion of the container lifting mechanism, wheel assembly, wheel positioning mechanism, and / or electrical components are integrally formed with at least one connection block.

[0028] To facilitate assembly of the frame or frame structure, optionally, one or more horizontal and / or vertical connecting elements comprise connecting rods or tubes. The connecting rods can be easily grasped and assembled into the connecting blocks in various rotational orientations. Assembly of the load handling device is thus facilitated by the connecting blocks and connecting rods. The frame is a three-dimensional frame structure that defines a volume for accommodating at least a portion of the lifting mechanism, and / or wheel assembly, and / or wheel positioning mechanism. Individual modular subframes are connectable, allowing various functions of the load handling device to be vertically stacked.

[0029] Optionally, the frame may comprise an open frame structure in which the internal operating components of the load handling device are visible from the exterior of the load handling device, such as, for example, the spools carrying the lifting tethers of the container lifting mechanism, and / or the power supply, and / or any one of the control units. The term open frame structure is interpreted as covering load handling devices that do not have an external cladding such that the internal components that provide the functional features of the load handling device are visible from the exterior.

[0030] The present invention provides an automated storage and retrieval system, a grid structure comprising a plurality of grid members, the grid members comprising a first set of grid members and a second set of grid members, the second set of grid members being substantially orthogonal to the first set of grid members such that the plurality of grid members are arranged in a grid pattern to guide movement of one or more load handling devices operating on the grid structure; at least one robotic load handling device according to the present invention operable on a grid structure; The present invention further provides an automated storage and retrieval system comprising:

[0031] Further features and aspects of the present invention will become apparent from the following detailed description of illustrative embodiments that proceeds with reference to the drawings. [Brief explanation of the drawings]

[0032] [Figure 1] 1 is a schematic view of a connecting block according to the present invention, comprising a socket for receiving a connecting element and fingers extending radially into the socket; [Figure 2] 2 is a schematic diagram showing a cross section of the connection block taken along line XX shown in FIG. 1; [Figure 3] Schematic diagram showing a cross-sectional view of a connecting block and a connecting element inserted into a socket. [Figure 4] Schematic diagram of a cross section of a connecting block and a connecting element inserted into a socket. [Figure 5](a) is a schematic cross-sectional view of a connecting block showing multiple sets of fingers extending radially from the inner wall of the socket, spaced along the longitudinal axis of the socket; (b) is a side view of a cross-section of a connecting block showing multiple sets of fingers spaced along the longitudinal axis YY. [Figure 6] 6 is a schematic diagram of a joint between the connecting block shown in FIG. 5 and a connecting element that engages with multiple fingers when inserted into a socket in the connecting block. [Figure 7] (a) is a schematic diagram showing various orientations of connecting elements in a connecting block depending on the cross-sectional shape of the socket and the orientation of the connecting elements in the socket to provide angle; (b) is a schematic diagram showing various orientations of connecting elements in a connecting block depending on the cross-sectional shape of the socket and the orientation of the connecting elements in the socket to provide eccentricity; (c) is a schematic diagram showing various orientations of connecting elements in a connecting block depending on the cross-sectional shape of the socket and the orientation of the connecting elements in the socket to provide ovality; and (d) is a schematic diagram showing various orientations of connecting elements in a connecting block depending on the cross-sectional shape of the socket and the orientation of the connecting elements in the socket to provide a combination of angle and ovality. [Figure 8] FIG. 10 is a schematic diagram of a front side view of a connecting block showing multiple radially extending fingers and inlet and outlet lumens extending into the socket. [Figure 9] 9 is a schematic cross-sectional view of the cross-sectional profile of the outlet lumen shown in FIG. 8 . [Figure 9b] Schematic diagram of a cross section of a connecting block showing a plurality of second type sets of fingers / fins extending radially from the inner wall of the socket spaced apart along the longitudinal axis XX of the socket. [Figure 9c] Schematic diagram of a cross section of a connecting block showing a plurality of second type sets of fingers / fins extending radially from the inner wall of the socket spaced apart along the longitudinal axis XX of the socket. [Figure 9d] 9(b) and 9(c) are schematic diagrams of front and side views of the connecting block of FIG. 9(b) and 9(c), showing the multiple radially extending fingers and the inlet lumen extending into the socket. [Figure 9e]9(b) to 9(d) are cross-sectional views of the connecting block shown in FIG. 9(b) to 9(d) in which the connecting element is inserted into the socket of the connecting block along the longitudinal axis XX of the socket. [Figure 10] 1 is a schematic diagram of a grid framework structure according to known systems; [Figure 11] 2 is a schematic diagram of a top view showing a stack of bins arranged within the framework structure of FIG. 1. [Figure 12] Schematic diagram of a known loading and unloading system for a material handling device operating on a grid framework structure. [Figure 13] 1 is a schematic perspective view of a material handling device showing a lifting device gripping a container from above; [Figure 14] 12A is a schematic perspective cutaway view of the loading device of FIG. 11 showing a container accommodated within the container receiving space of the loading device; FIG. 12B is a schematic perspective cutaway view of the loading device of FIG. 11 showing the container receiving space of the loading device; [Figure 15] 1 is a perspective view of a grabber device engaging a storage container according to the present invention; [Figure 16a] 1 is a schematic diagram of a load handling device according to an embodiment of the present invention; [Figure 16b] 1 is a schematic diagram of a loading device showing the lowering of a power source into a receptacle in accordance with an embodiment of the present invention; [Figure 17] (a) is a schematic diagram of the various modular sections of the load handling device shown in Figure 16, and (b) is a schematic diagram of a separate rectangular frame made up of four connecting blocks that resemble the various modular sections. [Figure 18] (a) is a schematic diagram of the assembly of modular sections shown in Figure 17(a) to form an open frame structure of a load handling device, and (b) is a schematic diagram of a simplified rectangular frame assembly of modular sections shown in Figure 17(b) to form an open frame structure of a load handling device. [Figure 19] Schematic diagram showing the assembly of connecting blocks to form a rectangular frame that is braced to form the middle halo of an open frame structure. [Figure 20] Schematic of one side of the frame showing the connections between the first modular section, the second modular section, and the third modular section. [Figure 21] Schematic drawing of the connecting blocks that make up the corner brackets of the second or intermediate modular section. [Figure 22] Schematic diagram of the connecting blocks that make up the corner brackets of the first or bottom modular section with wheel mounts. [Figure 23] Schematic of one side of the frame showing the connections between the first modular section, the second modular section, and the third modular section. [Figure 24] Schematic of a top view of an assembly of connection blocks and connection elements in a jig that provides a portion of the frame of a load handling device. [Figure 25] Schematic of a side view of an assembly of connection blocks and connection elements in a jig that provides a portion of the frame of a load handling device. DETAILED DESCRIPTION OF THE INVENTION

[0033] Frames or similar structures are used in a variety of applications and are distinguished from shell-shaped or solid structures by the purpose of their design. While shell structures use external strength to maintain their shape when supporting internal loads, frame structures are designed to support external and / or internal loads. The advantage of frame structures over solid structures is that they can be constructed from lightweight materials. When a frame forms part of a structure that includes various functional components for the structure's operation, the frame must be load-bearing to support the various functional components of the structure. In addition to being load-bearing, the frame must also be sufficiently rigid to ensure that the dimensional tolerances of the frame do not change under applied external forces. Examples of structures requiring the use of frames that are both load-bearing and rigid include, but are not limited to, bicycle frames and various other vehicle frames.

[0034] Typically, a frame or structure is composed of separate load-bearing elements that are assembled together. Various fasteners and / or adhesives can be used to connect the separate load-bearing elements. The physical characteristics of the load-bearing elements, such as bending stiffness, depend largely on the application of the structure. An example of a structure configuration comprising a frame according to the present invention is that of a robotic material handling device for lifting and moving one or more stacked containers in an inbound / outbound system. The inbound / outbound system typically comprises a grid structure comprising a plurality of grid members, the grid members comprising a first set of grid members and a second set of grid members, the second set of grid members being arranged substantially orthogonal to the first set of grid members in a grid pattern that guides movement of the material handling device on the grid structure. Further details of the inbound / outbound system are provided below.

[0035] Connecting blocks are used to connect load-bearing connecting elements in the construction of frames. The connecting elements can be any linear connecting element, including, but not limited to, rods, tubes, or pipes, and can comprise plastic, metal, and / or ceramic materials, and / or composite materials. An example of a composite material that possesses the necessary physical characteristics of light weight, high stiffness, high tensile strength, and high specific strength is carbon fiber in a polymer matrix. Various techniques can be used to secure the connecting blocks to the connecting elements. These include the use of adhesives or glues, fasteners or welding, or a combination of any one of these fastening methods. Using adhesives to secure the connecting blocks to the connecting elements appears to be the most efficient and cost-effective method for assembling frames. While various commercially available adhesives have the required adhesive strength to secure the connecting elements to the connecting blocks, the adhesive's ability to achieve a secure connection between the connecting blocks and the connecting elements depends largely on the surface contact area of ​​the adhesive between the connecting block and the connecting elements. The greater the adhesive surface area between the connecting block and the connecting elements, the greater the adhesive's strength, since more adhesive can contribute to the bond between the connecting block and the connecting elements.

[0036] A schematic diagram of a connecting block 2 for connecting connecting elements according to the present invention is shown in FIG. 1. The connecting block 2 includes a body 4 with a socket or opening 6 for inserting a connecting element 8 into the connecting block 2 (see FIG. 3). When the connecting element is a rod, the strength of the bond between the rod and the socket having an inner wall 10 depends largely on the spread of adhesive along the connecting end 12 of the rod. In the present invention, the connecting end of the connecting element represents the length of the connecting element inserted into the socket of the connecting block. Simply coating one end of the connecting element with adhesive and inserting the connecting element into the socket 6 of the connecting block 2 creates a problem in that excess adhesive may squeeze out of the inlet or mouth 14 of the socket 6, especially if the socket is a blind hole and adhesive pools at the socket entrance. This is unsightly and can also result in other geometric defects during assembly of a frame including the connecting block. Second, coating the connecting end 12 of the connecting element makes it less conducive to assembling multiple connecting blocks with the connecting elements before fastening or adhering the connecting blocks to the connecting elements with adhesive. This is especially true when multiple connecting blocks and connecting elements are assembled in a jig or fixture to ensure that the connecting blocks are accurately positioned and aligned relative to the connecting elements during assembly. This problem is exacerbated when the adhesive used to secure the connecting blocks to the connecting elements has a relatively short cure time after application. This problem is not limited to connecting blocks in the construction of frame structures that support components that provide the functional features of a structure, but can exist when connecting any type of connecting block to a connecting element, such as a rod.

[0037] Therefore, there is a need for a joint that can secure connecting blocks with connecting elements without the above-mentioned drawbacks. For the avoidance of doubt, the term "joint" also covers bonding between connecting blocks and connecting elements. Ideally, the adhesive in fluid form is introduced into the sockets of the connecting block after the connecting ends of the connecting elements are inserted into the sockets. This allows multiple connecting elements to be assembled before bonding or fastening them to their respective connecting blocks. This also allows for the use of a jig or fixture to control the precision or accuracy of alignment between the connecting elements and the connecting blocks, thereby allowing the frame to be constructed to predetermined dimensional tolerances. In certain embodiments of the present invention, the cross-sectional dimensions of the socket or opening 6 in the connecting block are intentionally made slightly larger than the cross-sectional dimensions of the connecting element 8 so that, when the connecting end 12 of the connecting element 8 is inserted into the socket, a space or gap 16 is created between the outer surface of the connecting end 12 of the connecting element 8 and the inner wall 10 of the socket (see FIGS. 3 and 4). This space or gap 16 is filled with adhesive when the connecting element is bonded to the connecting block. When the socket or opening 6 in the connecting block is cylindrical to accommodate a rod or tube, as shown in the specific embodiment illustrated in Figures 3 and 4, the diameter of the socket is slightly larger than the outer diameter of the rod or tube. By definition, the space 16 between the outer surface of the connecting end of the connecting element and the inner wall of the socket is called a "glue channel" because it occurs when the connecting end 12 of the connecting element 8 is inserted into the socket 6 to form a passage for accommodating adhesive.

[0038] In addition to providing space for adhesive filling, the space or gap 16 around the exterior surface of the connecting element when inserted into the socket of the connecting block also allows the connecting end of the connecting element to be moved at various orientations within the socket or opening 6 of the connecting block. For purposes of this definition, various orientations of the connecting element when inserted into the socket of the connecting block include any angle offset from the longitudinal axis of the socket. Various offset angles from the longitudinal axis XX of the socket are illustrated by the dashed lines AA and BB shown in FIG. 4 . Typically, the connecting element is inserted into the socket in a direction along an axis corresponding to the longitudinal axis of the socket. This is considered the default position of the connecting element within the socket. However, the slightly larger inner diameter of the socket compared to the outer diameter of the connecting element allows the connecting element to be moved at an angle offset from the longitudinal axis of the socket, which allows the orientation of the connecting element relative to the connecting block to be adjusted when assembling the frame with a jig or fixture. Without the ability to move the connecting elements relative to one another in multiple orientations within a jig or fixture when assembling a frame or subframe, there is a risk that the assembly may not meet the required dimensional tolerances and / or shape when the frame is built. Adjustment of the connecting elements relative to the connecting blocks allows the assembled frame to be adjusted to the required tolerances in size and / or shape.

[0039] If the assembly forms part of a larger frame, such as a subframe, any difference in the dimensions or geometry of the subframe will be apparent when the larger frame is assembled. Such differences in the dimensions and / or geometry of the subframe can affect the functional characteristics of the structure that includes the frame. For example, if the frame forms part of a structure that includes wheels on its surface for steering the structure, such as a vehicle, any difference in the dimensions and / or geometry of the subframe can adversely affect the alignment of the wheels attached to the frame. In a worst-case scenario, a difference in the dimensions of one of the subframes could result in a pair of wheels at the front and rear of the vehicle becoming misaligned, causing the vehicle to yaw or be driven at an off-lead angle. This difference in the dimensions and / or geometry of the assembled frame can be largely attributed to differences in the dimensional tolerances of the connecting blocks and / or connecting elements. A variety of forming techniques can be used to form the connecting blocks. These include, but are not limited to, various molding techniques, including additive manufacturing (3D printing), injection molding, casting, etc. However, the reproducibility of molded parts depends on several factors or conditions that cannot usually be precisely controlled, including, but not limited to, environmental conditions such as temperature, consistency of raw materials, etc. Although strict quality control measures are used to ensure the reproducibility of molded parts, there are still variations in the reproducibility of similar parts that ultimately manifest as differences in one or more dimensions or geometries of the frame that comprises the molded part.

[0040] To mitigate such variations in the assembly of a frame or subframe, a jig or fixture is typically used to ensure that the connection elements are precisely aligned and / or oriented within the subframe or frame. The jig or fixture controls the position of the connection blocks and connection elements, providing repeatability, accuracy, and interchangeability in the manufacture of the frame or subframe. An example of a jig or fixture 18 used to assemble a subframe in the construction of a robotic load handling device is shown in FIGS. 21 and 22. Typically, the jig or fixture 214 includes one or more mounting blocks 220 and / or clamps 218 with one or more reference points or guides that control the orientation of the connection elements relative to the connecting blocks of the present invention, i.e., it is a workpiece holding device that holds, supports, and positions the connection block and / or connection elements during assembly. Proper positioning of the connection element 184 with the connecting block 140d using the jig or fixture 214 shown in FIGS. 21 and 22 may involve movement of the connection element relative to the connecting block. As mentioned above, the cross-sectional dimension of the socket 6 is intentionally larger than the outer cross-sectional dimension of the connecting element, i.e., the diameter of the rod or tube in the case of a rod or tube, to allow the orientation of the connecting element to be changed as it is inserted into the connecting block. Movement of the connecting element within the socket allows for various orientations of the connecting element relative to the connecting block depending on a reference point within the fixture or jig. Examples of various orientations of the connecting element 8 within the socket 6 of the connecting block are shown in Figures 7(a) through 7(d). Cross sections of the assembled socket are shown adjacent to the corresponding Figures 7(a) and 7(d). These examples include, but are not limited to, angular orientation, where the connecting element 8 is oriented at an angle to the longitudinal axis of the socket 6 (see Figure 7a); eccentric orientation, where the connecting element 8 is offset from the center of the socket 6, i.e., offset laterally from the longitudinal axis of the socket (see Figure 7b); oval orientation, where the socket cross section is oval or elliptical (see Figure 7c); and any combination of the above (see Figure 7d).

[0041] To initially center the connecting end of the connecting element within the socket or opening of the connecting block, i.e., along the longitudinal axis of the socket, while still allowing the connecting end of the connecting element to move within the socket if adjustments are needed during assembly in a jig or fixture, a plurality of fingers or fins 24 are disposed within the socket 6, as shown in FIG. 2, resiliently biased to extend radially inward from the inner wall 10 of the socket. More specifically, the inner wall includes a side wall 11, and the plurality of fingers or fins 24 are resiliently biased to extend radially inward from the side wall 11 of the socket 6. Each of the plurality of fingers 24 has a first end 26 fixed to the inner wall 10 of the socket 6 and a second end 28 that freely contacts the outer surface of the connecting end 12 of the connecting element 8 when inserted into the socket (see FIG. 4). In the particular example of the invention shown in FIGS. 1-6, each of the plurality of fingers is formed as a discrete, elongated member extending radially from the inner wall of the socket 6. The plurality of fingers or fins are secured to the inner wall of the socket such that each of the plurality of fingers or fins is pivotable about a respective first end 26 secured to the inner wall of the socket. The plurality of fingers 24 are configured to guide the connecting end of the connecting element toward the center of the socket when inserted into the socket, as shown in FIG. 4, so that the connecting end of the connecting element is inserted into the socket along an axis corresponding to the longitudinal axis of the socket.

[0042] Each of the plurality of fingers or fins is configured to deflect under a force applied when the connecting end of the connecting element is inserted into the socket. In certain embodiments of the invention, the plurality of fingers are made of a resilient material, such as a plastic material, that can deform under an applied force and return to its original position when the applied force is removed, so that one or more of the plurality of fingers or fins can conform to the contour of the connecting end of the connecting element.

[0043] The connections between each of the fingers 24 and the inner wall of the socket are prone to fatigue due to the concentration of stress around this area, creating a risk of failure at the connections. In a worst-case scenario, fatigue at the connections could cause one or more of the fingers to break away from the inner wall of the socket. Furthermore, fatigue at the joints between each of the fingers and the inner wall of the socket limits the range of movement of the fingers. To mitigate this fatigue, the inner wall 10 of the socket 6 includes recesses 30 at the joints between each of the fingers and the inner wall of the socket (see FIG. 6 ) to allow each of the fingers to pivot about their respective attachment points. The recesses 30 act to distribute stress around the joint rather than concentrating it at a single point.

[0044] As shown in FIGS. 3 and 4 , the fingers 24 are arranged around the inner peripheral wall 10 of the socket and extend radially inward toward the center of the socket. Each of the fingers forms an acute angle α with the inner wall of the socket (see FIG. 6 ) such that the fingers 24 form a frusto-conical shape within the socket, having an opening 32 substantially concentric with the opening 14 of the socket 6 (see FIGS. 2 and 8 ). In other words, the fingers are arranged circumferentially around the inner wall of the socket such that their free or second ends form openings 32 concentric with the opening or mouth of the socket. Thus, by definition, the term “radial” with respect to the fingers covers any angle α that each of the fingers makes with the inner wall of the socket of 90° or less. In the particular embodiment of the invention shown in FIG. 6 , each of the fingers or fins forms an acute angle with the inner wall of the socket. As shown in FIG. 2 , the fingers 24 are arranged around the inner peripheral wall of the socket to define an opening 32 that receives the connecting end of the connecting element, concentric with the opening 14 of the socket. The fingers 24 are angled relative to the inner wall of the socket so that the opening 32 defined by the second free ends of the fingers has a diameter less than the cross-sectional diameter of the connecting element. As a result, the free second end 28 of each of the fingers or fins engages or contacts the outer surface of the connecting end 12 of the connecting element when the connecting end is inserted into the socket (see FIGS. 3 and 4 ). The resilient nature of the fingers 24 allows them to conform to the connecting end 12 of the connecting element 8 by flexing around the connection with the inner wall of the socket, as shown in FIGS. 3 and 4 . The fingers help guide the connecting end of the connecting element toward the center of the socket when the connecting end is inserted into the socket 6 along the longitudinal axis of the socket. To assist in guiding the connecting end of the connecting element into the socket, the second end 28 of each of the plurality of fingers is tapered or has an inclined surface configured to cooperate with the exterior surface of the connecting end of the connecting element as shown in FIG.

[0045] To provide additional support to the connecting end of the connection element when inserted into the socket, one or more sets of fingers may be disposed within the socket, each of the one or more sets comprising a plurality of the above-described fingers. In the particular embodiment shown in FIG. 2, a first set 34 of fingers and a second set 36 of fingers are shown spaced apart along the longitudinal axis of the socket. The first set 34 of fingers and the second set 36 of fingers guide the connecting end of the connection element when inserted into the socket so that the axis XX extending longitudinally along the center of the connection element is substantially coaxial with the axis extending longitudinally along the center of the socket (see FIGS. 3 and 4). This is considered the default or natural position of the connecting end of the connection element when inserted into the socket 6. The resilience of the plurality of fingers 24 allows the connecting end of the connection element to move within the socket. However, the present invention is limited to having first and second sets of fingers as shown in FIG. 2, and any number of sets of fingers are possible. The number of sets of fingers will depend largely on the depth of the socket and the support required when the connecting end of the connecting element is inserted into the socket. A relatively deep socket may require more sets of fingers spaced longitudinally along the length of the socket to stabilize the connecting end of the connecting element within the socket than a relatively small deep socket. For example, Figures 5(a and b) show a connecting block 2 with three sets of fingers 34, 36, 38 spaced along the longitudinal axis XX of the socket, each of which is arranged around the inner wall of the socket to form an opening substantially concentric with the socket opening.

[0046] Once the connecting elements are properly positioned within the sockets of the respective connecting blocks, guided by the jig or fixture, adhesive is used to fix the position and / or orientation of the connecting elements relative to the respective connecting blocks. To apply adhesive to the connecting ends of the connecting elements after they are inserted into the connecting blocks, the adhesive is injected into the sockets through an opening on the exterior of the connecting block. In a specific embodiment of the present invention, the connecting block includes an injection port or injection point 40 having an injection port lumen 42 extending along a second axis YY from an opening 44 on the exterior of the connecting block to an opening 46 in the interior wall of the socket for injecting adhesive into the socket (see FIGS. 1, 2, and 5). The first axis is an axis aligned with the longitudinal axis of the socket. The second axis or injection port axis YY is angled such that the second axis forms an acute or obtuse angle with the first axis corresponding to the longitudinal axis of the socket (see FIG. 2). The angle of the second axis relative to the first axis can be any angle that allows adhesive to be injected into the socket. Optionally, the angle between the first axis and the second axis may range from 35° to 135°. In the specific embodiment of the invention shown in FIG. 2, the second axis YY is substantially perpendicular to the first axis XX, corresponding to an angle of 90°. This allows adhesive to be injected directly into the socket 6 (along the glue channel) after the connecting end of the connecting element is inserted into the socket. In the specific embodiment of the invention shown in FIG. 2, the first axis intersects with the second axis. However, the invention is not limited to the first axis intersecting with the second axis.

[0047] Injecting adhesive into the sockets of the connecting blocks presents another problem: the adhesive must be retained within the socket until it cures. Once cured, there is limited opportunity to adjust the orientation of the connecting elements relative to their respective connecting blocks. Without any retention mechanism, there is a risk that after the adhesive is injected into the socket, some of the adhesive will escape through the socket opening or mouth 14, reducing adhesive coverage on the connecting ends of the connecting elements within the socket. This could affect the strength of the bond between the connecting elements and the connecting blocks. Therefore, in addition to guiding the connecting ends of the connecting elements toward the center of the socket, i.e., along the longitudinal axis of the socket, a plurality of radially extending fingers 24 arranged around the inner peripheral wall 10 of the socket cooperate with the connecting ends of the connecting elements to provide a degree of resistance or barrier that prevents the adhesive from leaking out of the socket. This resistance can be determined by the level of adhesive confinement within the socket. In the specific embodiment of the present invention shown in FIGS. 2 and 5, the spacing or separation between the individual fingers can be used to control the amount of adhesive that can be trapped within the socket. As shown in Figures 5(a and 5b), a relatively large separation between adjacent fingers minimizes adhesive trapping because the adhesive can flow between the separated fingers, while a relatively small separation between adjacent fingers largely prevents adhesive from flowing between the separated fingers, maximizing adhesive trapping. The separation or gap between adjacent fingers also depends on the viscosity of the adhesive. With a relatively high viscosity or thick adhesive, a larger separation between adjacent fingers may be sufficient to trap a sufficient amount of adhesive within the socket compared to a relatively low viscosity or thin adhesive. Depending on the viscosity range of the adhesive, the separation or gap between adjacent fingers can be in the range of 0.1 mm to 1 mm, optionally in the range of 0.1 mm to 0.5 mm.

[0048] While the specific example of the present invention described above describes the fingers as discrete, elongated members, the present invention is not limited to the fingers being formed as elongated members. For example, the fingers can be arranged so that adjacent fingers at least partially overlap one another, as shown in the specific example shown in Figures 9(b) through 9(e). Like the fingers described with reference to Figures 1 through 5, the fingers in the second example shown in Figures 9(b) through 9(e) are spaced apart to allow fluids, such as air, to pass between the fingers while still providing a barrier that at least prevents adhesive from flowing beyond the fingers, thereby helping to confine the adhesive within the socket. A problem with forming the fingers as elongated members is that the spacing between adjacent fingers tends to be too small to allow air to pass through the spaces between adjacent fingers. This is particularly exacerbated when the connecting end of the connecting element is inserted into a socket in a connecting block. Because the fingers are compliant, the spacing between adjacent fingers tends to close significantly as the fingers conform to the contour of the connecting element when inserted into the socket. In a worst case scenario, the air pressure upstream of the adhesive will be so high that it will prevent the adhesive from reaching the fingers and fully covering the connecting end of the connecting element, i.e., filling the glue channel.

[0049] In a second example of a connecting block 102, the fingers 124 shown in FIGS. 9(b) through 9(e) are arranged circumferentially around the inner wall 10 of the socket 6 such that adjacent fingers 124 at least partially overlap. The overlapping regions of the fingers 124 allow adjacent fingers to contact one another when the connecting ends of the connecting element are inserted into the socket (see FIG. 9e), yet still provide a passageway for air to circulate through the fingers. In other words, the at least partially overlapping fingers 124 prevent the spacing between adjacent fingers from completely closing. To maximize the degree of overlap between adjacent fingers, the first or connecting end 125 of each of the fingers is secured to a larger portion of the inner wall 10 of the socket compared to the elongated members shown in FIGS. 1 through 5. In the second example shown in FIGS. 9(b) through 9(d), the fingers 124 are formed as discrete fins or blades arranged in a "turbo" blade design. Each of the multiple fingers has a triangular shape such that the width of the first "connecting" end 125 of the fin is greater than the second "free" end 126 of the fin and is secured to the inner wall of the socket. When the spacing between adjacent fins or blades closes, i.e., when the connecting end of the connecting element is inserted into the socket 6, the spacing between adjacent fins at the foot or first end 125 of each of the multiple fins or blades remains open, providing a path for air to escape, while the overlapping fins (near the second end 126 of the fin) minimize the flow of the more viscous adhesive between the multiple fins or blades. Airflow through the multiple fins minimizes the flow resistance of the adhesive in the glue channel as a result of the air passing through the multiple fins, allowing more adhesive to be injected into the socket (i.e., into the glue channel). The shape of each fin is not limited to a triangle; any other shape is acceptable in the present invention as long as adjacent fins at least partially overlap. For example, each of the multiple fins could be square.

[0050] The location of the inlet 40 relative to the fingers also affects adhesive containment within the socket. Ideally, the fingers are positioned at the entrance or mouth 14 of the socket to maximize adhesive containment at the socket mouth. In the particular embodiment shown in FIG. 2 , the first set of fingers 26 are located at the entrance or mouth of the socket, and the inlet 40 is positioned further back in the socket than the first set of fingers so that adhesive injected into the socket through the inlet 40 will flow around the connecting end of the connecting element, i.e., along the glue channel 16, which is the path of least resistance, rather than through the fingers. As a result, adhesive has a greater tendency to fill the glue channel 16 before being trapped by the fingers, thereby achieving a more effective bond between the connecting element and the connecting block.

[0051] Because multiple fingers can at least confine the adhesive within the socket, multiple sets of fingers can also be used to control the coverage of the adhesive on the connection end 12 of the connection element 8 inserted into the socket, i.e., to control the size or length of the glue channel (see FIG. 4). It may not be necessary to cover the entire connection end of the connection element to achieve a predetermined bond strength between the connection element and the connecting block. For example, the bond strength between the connection element and the connecting block is highly dependent on the amount of adhesive injected into the socket, reaching a point of diminishing returns in bond strength when a predetermined amount of adhesive is injected into the socket. Surprisingly, it has been found that having little or no adhesive on the free or distal end of the connection end of the connection element has little effect on the bond strength between the connection element and the connecting block. This has the advantage of reducing the amount of adhesive required to bond the connection element to the connecting block to achieve a predetermined bond strength. Using more adhesive than this amount only results in limited improvement in bond strength or diminishing returns. When the connecting elements are tubes or hollow rods, limiting the amount of adhesive that reaches the free or distal end of the connecting elements also reduces the amount of adhesive that enters the hollow portion of the connecting elements. Given that assembling a frame structure requires multiple joints between numerous connecting elements and connecting blocks, reducing the amount of adhesive at each joint will affect the total amount, and therefore the cost, of the adhesive used to construct the frame of the load handling device. This is especially true when specialized adhesives with specific physical characteristics are used to construct the frame.

[0052] In a particular embodiment of the invention shown in FIG. 4, the second set of fingers 38 are spaced apart from the first set of fingers 36 by a length "L" along the longitudinal axis of the socket such that an inlet 40 is positioned between the first set of fingers 36 and the second set of fingers 38 (see FIG. 2). The separation between the first set of fingers 36 and the second set of fingers 38 defines the length "L" of the glue channel that ultimately controls the bond strength (see FIG. 4). Adhesive injected into the socket via the inlet is confined between at least the first set of fingers 36 and the second set of fingers 38 to ensure sufficient adhesive coverage around the most critical portions of the connection ends of the connection elements between the first and second sets of fingers, and little or no adhesive around the least critical portions of the connection ends of the connection elements that have little or no effect on bond strength. When the socket is a blind hole having end walls, as shown in the particular embodiment of the invention shown in FIG. 4, the second set of fingers 38 are recessed from the end walls of the socket to limit the amount of adhesive that reaches the distal end of the connecting element adjacent the end walls of the socket, which has only a limited effect on the bond strength, thereby shortening the length "L" of the glue channel.

[0053] Similar to the first example of the connecting block described with reference to FIG. 2, the plurality of fins 124 described with reference to FIGS. 9(b) through 9(e) includes a first set of fins 134 disposed at the entrance or mouth of the socket and a second set of fins spaced apart in a direction along the longitudinal axis XX of the socket. An inlet 40 for injecting adhesive into the socket is disposed between the first and second sets of fins such that adhesive injected into the socket is confined in the glue channel region between the first and second sets of fins. At least partially overlapping fins can provide a passageway for airflow while minimizing the flow of high-viscosity adhesive through the plurality of fins, allowing more adhesive to flow between the first and second sets of fins and providing greater adhesive coverage on the connecting ends of the connecting element.

[0054] The fingers are configured to cooperate with the connecting end of the connecting element to achieve containment of the adhesive within the socket, but separation of the fingers must allow thinner fluids, such as air, to pass through the fingers. When adhesive is injected into the socket through the inlet 40, the pressure of the fluid, e.g., air, within the socket increases as the adhesive fills the glue channel, particularly around the glue channel 16. Without a means to relieve this pressure, the increase in pressure at the adhesive front would affect the amount of adhesive injected into the socket 6, thereby significantly affecting the fill rate of the socket, i.e., the adhesive within the glue channel. To relieve this pressure, the connecting block further includes an outlet or discharge hole 48 having an outlet lumen 50 extending along a third axis OO from an opening 54 in the interior wall (side wall) of the socket to an outlet opening 52 on the exterior of the connecting block, for venting fluid from the socket. Similar to the inlet, the third axis OO is oriented at an angle to the first axis XX, which corresponds to the longitudinal axis of the socket. The angle that the third axis makes with the first axis can be any angle that allows for the release of fluid from the socket. Optionally, the angle that the first axis makes with the third axis can range from 35° to 135°. In the specific example of the invention shown in FIG. 8, the third axis OO is substantially perpendicular to the first axis XX, which corresponds to a 90° angle. This allows air trapped in the socket to be released directly from the socket 6 (along the glue channel) after adhesive is injected into the glue channel. Although not shown in FIG. 8, the third axis can also intersect with the first axis of the socket.

[0055] The outlets or holes 48 also provide an indication of the state of adhesive fill in the socket. Thus, the holes also provide an indication of the adhesive-holding capacity of the socket, and more particularly, the glue channel. Thus, adhesive emerging from the holes or holes 48 provides an indication that adhesive has sufficiently filled the glue channel. One or more holes or holes 48 are strategically positioned around the connecting block and are in fluid communication with various portions of the socket 6 or glue channel 16 to release trapped air within the socket and provide an indication of the state of fill of the various portions of the socket 6 or glue channel 16. In the particular embodiment of the invention shown in FIG. 1 , four holes 48 are shown positioned between the first and second sets of fingers, each of which provides an indication of the rate at which adhesive is filling at least a portion of the socket or glue channel. The pattern of the holes is determined by the rate at which adhesive is filling the various portions of the glue channel. The four discharge holes 48 are shown arranged in a quincunx pattern, one at each corner of a square or rectangle with the inlet opening 40 in the middle. The amount of adhesive that exits the discharge holes 48 is highly dependent on the fill capacity of the socket or glue channel 16 and the manner in which the adhesive fills the socket or glue channel. Adhesive will exit first through the discharge hole in fluid communication with the corresponding portion of the socket or glue channel that is filled first, and subsequently through the discharge holes in fluid communication with the corresponding portions as other portions of the socket or glue channel are filled with adhesive. The discharge holes are also shown as being located on the same wall as the inlet 40 of the connecting block. This is to ensure that adhesive injected into the socket through the inlet fully fills the glue channel 16.

[0056] Another important consideration is the flow rate of adhesive in the socket or glue channel after the adhesive is injected into the socket. By definition, adhesive "flow rate" is interpreted to mean the volumetric flow rate of fluid in the socket or glue channel, i.e., Q = V / t. Here, V is the volume of fluid passing through a given cross-sectional area of ​​the glue channel, t is the time required to pass through that given cross-sectional area of ​​the glue channel, and Q is the volume of fluid passing through that given cross-sectional area of ​​the glue channel per unit time. The flow rate of adhesive through the glue channel is largely controlled by the pressure applied to the adhesive as it is injected into the socket through the inlet 40, but it is also controlled by the rate at which trapped fluid, such as air, in the glue channel is released through the outlet 48. For a given injection rate of adhesive into the socket, the greater the restriction of fluid that can be released through the outlet 48, the slower the rate at which adhesive can flow through the socket or glue channel because the flow of adhesive along the glue channel is impeded by the increased pressure in the socket or glue channel. Conversely, the smaller the restriction on the fluid that can be discharged from the discharge hole, the greater the rate at which the adhesive can flow through the socket or glue channel, since there is less obstruction to the flow of adhesive within the socket or along the glue channel. The cross-sectional dimension (e.g., diameter) of the outlet lumen 50 can affect the rate at which the adhesive flows within the socket or along the glue channel. By controlling the cross-sectional dimension of the outlet lumen 50, the flow rate of adhesive within or along the socket can be controlled.

[0057] However, while the smaller cross-sectional dimension of the outlet lumen 50 restricts fluid flow through the outlet or release hole 48, the outlet lumen tends to fill with adhesive quickly after at least a portion of the glue channel is filled with adhesive due to the smaller volume capacity of the outlet lumen. In a worst-case scenario, the smaller volume capacity of the outlet lumen tends to cause the outlet lumen 50 to overflow with adhesive. Without a means to capture this overflow, the adhesive may drip onto other areas of the frame. To alleviate this problem, the cross-sectional dimension of the outlet lumen 50 is varied to change the volume and therefore the velocity of the fluid within the outlet lumen. For example, the outlet lumen can include a first portion 56 having a first cross-sectional dimension and a second portion 58 having a second cross-sectional dimension, the second cross-sectional dimension being different from the first cross-sectional dimension such that the velocity of fluid through the first portion 56 is different from the second portion 58 for a given applied pressure of adhesive. An advantage of an outlet hole or outlet with an outlet lumen having varying cross-sectional dimensions is that a first portion of the outlet lumen can be used to constrict the fluid flow through the outlet hole, thereby allowing the adhesive to fully fill the glue channel, while a second portion of the outlet lumen can capture any adhesive overflow from the first portion of the outlet with its larger volumetric capacity. This can be explained by the following simple fluid flow equation (Equation 1) in conjunction with the outlet lumen cross-section shown in FIG. 9: Assuming the fluid is an incompressible liquid, the volumetric flow rate of the fluid through the first portion 56 of the outlet lumen can be equal to the volumetric flow rate of the fluid through the second portion 58 of the outlet lumen. Q1=Q2(1) where Q1 is the volumetric flow rate of the liquid fluid through the first portion of the outlet lumen and Q2 is the volumetric flow rate of the liquid fluid through the second portion of the outlet lumen.

[0058] Hypothetically, this could be considered equivalent to: A1v1=A2v2(2) where A1 is the fluid cross-sectional area of ​​the first portion of the outlet lumen; A2 is the fluid cross-sectional area of ​​the second portion of the outlet lumen; v1 is the velocity of the fluid in the first portion of the outlet lumen; v2 is the velocity of the fluid in the second portion of the outlet lumen.

[0059] In the specific embodiment of the invention shown in Figures 8 and 9, the first portion 56 of the outlet lumen 50, extending from the opening 54 in the interior (side) wall of the socket, has a smaller cross-sectional dimension d1 than the second portion 56 of the outlet lumen 50, which has a larger cross-sectional dimension d2 and continues to the opening 52 on the exterior of the connecting block. This means that the outlet lumen has a funnel-shaped configuration. The smaller cross-sectional dimension d1 of the first portion 56 of the outlet lumen limits the velocity of fluid through the first portion of the outlet lumen, thus affecting the rate at which the glue channels fill with adhesive and allowing more time for the adhesive to fully fill the glue channels. The larger cross-sectional dimension d2 of the second portion 58 of the outlet lumen 50 captures any overflow from the first portion 56, thereby providing a sufficient delay to prevent adhesive from overflowing from the second portion 58 of the outlet lumen and exiting the outlet. The adhesive emerging from the second portion 58 of the outlet lumen provides an indication that the adhesive has substantially filled the glue channel, in which case further injection of adhesive into the inlet 40 can be stopped.

[0060] The sockets in the connecting blocks are not limited to blind holes as shown in FIGS. 1 to 7 but may also be through-holes, in which case at least one of the sets of fingers is disposed within the through-hole. This may be a single set of fingers or multiple sets of fingers as exemplified by the sockets shown in FIGS. 2 or 5(a and 5b). Furthermore, connecting blocks according to the present invention are not limited to a single socket but may also include multiple sockets, each with at least one set of fingers disposed within the socket for guiding the connecting end of a connecting element toward the center of its respective socket. Each of the multiple sockets may be a blind hole or a through-hole, or a combination of blind and through-holes. For example, as exemplified by the connecting block shown in FIG. 19, it may be necessary for a connecting block to include both blind and through-hole sockets. In FIG. 19, the function of which will be described later, the connecting block includes multiple blind holes for connecting the connecting block to two other connecting blocks in the same horizontal plane to form a rectangular modular subframe, and through-holes for connecting multiple rectangular modular subframes in a vertical stack. The modular subframe may be a rectangular modular subframe, as shown in FIG. 19. The first axes of each of the plurality of sockets, corresponding to the longitudinal axis of the socket, may be arranged so that they form acute or obtuse angles with one another. This is particularly true when the connecting block includes a first socket and a second socket, where the first socket is a blind hole and the second socket is a through hole. The angle of their respective first axes may be any angle, for example, between 35° and 135°, that allows connecting elements to be separately connected to the connecting block. In the specific embodiment of the invention shown in FIG. 19, the first axis of the first socket with the blind hole is substantially perpendicular to the first axis of the second socket with the through hole. Although not essential, the first axis of the first socket forming the blind hole may optionally intersect the first axis of the second socket forming the through hole (see FIG. 19).Intersecting the first axis of each socket of a given connecting block provides symmetry to the modular subframe when at least four connecting blocks are assembled with connecting elements.

[0061] The use of the connecting block according to the present invention allows for the adjustment of the orientation of one or more of the connecting elements when assembled, thereby enabling various frames or frame structures to be assembled with the required dimensional tolerances. One particular structure that is highly dependent on the dimensional tolerances of the frame or frame structure is the configuration of a robotic material handling device. The configuration of a robotic material handling device in the field of storage and retrieval systems is used as an example of the configuration of a frame based on the connecting block according to the present invention described above.

[0062] Intake and retrieval system Inbound and outbound systems 60 comprising a three-dimensional storage grid framework structure 66 in which storage containers / bins are stacked one on top of the other are known. PCT Publication No. WO2015 / 185628A (Ocado) describes a known storage and fulfillment or distribution system in which stacks of bins or containers are arranged within a grid framework structure. The bins or containers are accessed by remotely operated robotic material handling devices on trucks located on top of the grid framework structure. A system of this type is shown schematically in Figures 10 to 12 of the accompanying drawings.

[0063] As shown in FIGS. 10 and 11 , stackable containers, called storage bins or containers 62, are stacked on top of each other to form stacks 64. The stacks 64 are arranged within a three-dimensional grid framework structure 66 in a warehouse or manufacturing environment. The grid framework structure 66 is composed of multiple storage columns or grid columns. Each grid in the grid framework structure has at least one grid column for storing stacks of containers. FIG. 10 is a schematic perspective view of the grid framework structure 66, and FIG. 11 is a top view showing the stack 64 of bins 62 arranged within the framework structure 66. Each bin 62 typically holds multiple product items (not shown), which may be the same or different product types depending on the application. The bins 62 may also be called storage bins or containers, or storage containers or totes.

[0064] Specifically, the three-dimensional grid framework structure 66 comprises a plurality of vertical support columns 68, or support members, or columns 68, that support horizontal grid members 70, 72. A first set of parallel horizontal grid members 70 are arranged orthogonally relative to a second set of parallel horizontal grid members 72 to form a grid structure or grid 74 comprising a plurality of grid cells 76. The grid cells have openings to allow a material handling device to lift containers or storage bins through the grid cells. In the grid structure, the first set of parallel horizontal grid members 70 intersect with the second set of parallel horizontal grid members at nodes 69. The grid structure can be supported by support members 68 at each node or point where the grid members intersect, such that the support members are interconnected at their upper ends by the intersecting grid members. The grid members 68, 70, 72 are typically made of metal and are typically fastened together by welding, bolting, or a combination of both. The storage bins or containers 62 are stacked between support members 68 of a grid framework structure 66 such that the support members 68 protect the stack 64 of bins 64 from horizontal movement and guide the vertical movement of the storage bins 62 .

[0065] The top layer of the grid framework structure 66 includes rails or tracks 78 arranged in a grid pattern across the tops of the stacks 64. With further reference to FIG. 12 , the rails 78 support a plurality of load handling devices 80. A first set 78 a of parallel rails 78 guides movement of the robotic load handling devices 80 in a first direction (e.g., the X direction) across the top of the grid framework structure 66, while a second set 78 b of parallel rails 78 arranged orthogonal to the first set 78 a guides movement of the load handling devices 80 in a second direction (e.g., the Y direction) orthogonal to the first direction. In this manner, the rails 78 enable movement of the robotic load handling devices 80 laterally in two dimensions within the horizontal XY plane, allowing the load handling devices 80 to be moved into position above any of the stacks 64.

[0066] A known load handling device or robotic load handling device, also referred to as a bot 80, comprising a vehicle body 82 shown in Figures 13 and 14 is described in PCT Patent Publication No. WO / 2015 / 019055 (Ocado), which is incorporated herein by reference, but in this case each load handling device 80 covers only a single grid space or grid cell of a grid framework structure 66. Here, the load handling device 80 comprises a wheel assembly comprising a first set of wheels 84 consisting of a pair of wheels at the front of the vehicle body 82 and a pair of wheels 84 at the rear of the vehicle 82 that engage with a first set of rails or tracks to guide movement of the device in a first direction, and a second set of wheels 86 consisting of a pair of wheels 86 on each side of the vehicle 82 that engage with a second set of rails or tracks to guide movement of the device in a second direction. Each of these sets of wheels is driven by a wheel drive assembly to enable movement of the vehicle in the X and Y directions along the rails, respectively. The diverting mechanism is configured to vertically lift one or both sets of wheels away from their respective rails to allow the vehicle to move in a desired direction, e.g., an X or Y direction, on the grid structure. For example, the diverting mechanism is configured to selectively lift the second set of wheels when the load handling device travels along a first direction and to selectively lift the first set of wheels when the load handling device travels along a second direction.

[0067] WO2017 / 153583 (Ocado Innovation Limited) teaches a load handling device comprising a wheel positioning or steering mechanism that allows either a first or second set of wheels to selectively engage with a first or second set of rails or tracks (62a or 62b), thereby enabling lateral movement of the device in one of two transverse directions. The wheel positioning mechanism comprises a complex arrangement of linkages driven by linear actuators or motors that selectively lower or raise the first set of wheels or the second set of wheels to engage or disengage with the first set of tracks or rails or the second set of tracks or rails.

[0068] The material handling device 80 includes a lifting mechanism, or container lifting mechanism, or crane mechanism for lifting a storage container from above. The crane mechanism includes a tether or cable 88 wound on a spool or reel (not shown) and a grabber device or container gripper assembly 89 in the form of a lifting frame. The terms "grabber device" and "container gripping assembly" are used interchangeably in this patent specification to refer to the same mechanism. The lifting mechanism includes a set of vertically extending lifting tethers 88 (one tether near each of the four corners of the lifting frame) near or connected to the four corners of the lifting frame 89 for releasable connection to the storage container 62. The grabber device 89 is configured to releasably grasp the top of the storage container 62 to lift the storage container 62 from a stack of containers in a storage system of the type shown in FIGS. 10 and 11 .

[0069] The wheels 84, 86 are arranged around a cavity or recess in the lower section, referred to as the container-receiving recess 91. This recess is sized to accommodate the container 62 when it is lifted by the crane mechanism, as shown in FIGS. 14(a) and 14(b). While in the recess, the container is lifted away from the rail below it, allowing the vehicle to move laterally to different locations. Upon reaching a target location, such as another stack, an access point in a storage system, or a conveyor belt, the bin or container can be lowered from the container-receiving section and released from the grabber device. The container-receiving space may comprise a cavity or recess arranged in the vehicle body, as described, for example, in WO 2015 / 019055 (Ocado Innovation Limited). Alternatively, the vehicle body of the load handling device may comprise a cantilever, in which case the container-receiving space is located below the cantilever of the load handling device, as taught in WO 2019 / 238702 (Autostore Technology, AS). In this case, the grabber device is lifted by the cantilever so that the grabber device can engage a container and lift the container from the stack into a container receiving space below the cantilever.

[0070] Power to the drive units that operate the lifting mechanism and wheel positioning mechanism is provided by a rechargeable power supply. The load handling device further includes one or more auxiliary electrical components, such as a controller, and one or more wire looms that carry information from the controller and / or power from the rechargeable power supply to the load handling device's drive units. One or more load handling devices remotely operable on the grid structure are configured to receive commands from a master controller to retrieve storage containers from specific storage locations within the grid framework structure. Wireless communications and networks may also be used to provide a communications infrastructure from the master controller through one or more base stations to one or more load handling devices operable on the grid structure. In response to receiving the commands, the load handling device's controller is configured to control various drive mechanisms to control the movement of the load handling device. For example, the load handling device may be instructed to retrieve a container from a storage column at a specific location on the grid structure. The commands may include various movements in the X and Y directions on the grid structure 74. Upon reaching the storage column, a lifting mechanism is operated to grab the storage container, lift it, and place it in a container-receiving space within the body of the load handling device, after which the storage container is transported to another location on the grid structure, commonly referred to as a discharge port. The container is lowered to an appropriate discharge station, allowing items to be removed from the storage container. Movement of the load handling device on the grid structure also includes commanding the load handling device to move to a charging station, typically located on the periphery of the grid structure. The load handling device remains stationary at the charging station while its batteries are recharged. The charging period is a significant source of downtime for the load handling device, which can be on the order of several hours. The rechargeable power source and auxiliary electrical components of the load handling device are typically housed within the body of the load handling device.

[0071] Typically, cargo handling devices in the art include a separate rigid framework or chassis, to which functional components of the cargo handling device, such as the container lifting mechanism, wheel positioning mechanism, wheel assembly, wheel drive assembly, and electrical components such as a rechargeable power source and / or control unit, are literally secured or attached. The securing includes various fasteners, such as bolts, screws, and / or welding. The framework is typically in the form of a tower with a height representative of the height of the cargo handling device. To ensure that the structural integrity of the rigid framework or chassis can support the weight of the various functional components of the cargo handling device, the rigid framework is generally constructed of a metal, such as aluminum or stainless steel. Cladding is secured to the outside of the framework to form a vehicle body that houses the functional mechanisms of the cargo handling device. The cumulative weight of the rigid framework and the various functional components of the cargo handling device can result in a cargo handling device weighing more than 150 kg. Due to the weight of the load handling devices, the grid framework structure 66 must have sufficient structural integrity to support the weight of multiple load handling devices operable thereon. Various bracing elements are used to increase the strength of the grid framework structure, which ultimately increases the cost of the grid framework structure and therefore the overall cost of the loading and unloading system. As the weight of the load handling device increases, more power is also required to drive the wheel motors to move the load handling device at a sufficient speed on the track, resulting in the need for larger and more powerful electric motors and larger batteries to provide the power needed to drive the electric motors.

[0072] Furthermore, the number of components, including various motors, pulleys, and electrical components such as batteries and control panels required for a load handling device to operate on a grid framework structure, and assembling these individual components, is one of the largest costs in manufacturing a load handling device. Considering that there are hundreds of load handling devices that can operate on a grid framework structure, the cumulative cost of multiple load handling devices that can operate on a grid structure accounts for a significant portion of the cost of a typical loading and unloading system. Not only does the cost of manufacturing the load handling devices account for a significant portion of the cost of the loading and unloading system, but the weight of the load handling devices, which can weigh more than 150 kg, can also lead to other additional costs. Therefore, there is a need for a load handling device that is easy to assemble, lightweight, and can be manufactured at low cost.

[0073] In accordance with embodiments of the present invention, the construction of a load handling device 130 is based on the principle of having a modular system with multiple modules or modular subframes connectable in a vertical stack to provide various functional features of the load handling device. In comparison to prior art load handling devices, a load handling device according to embodiments of the present invention has no cladding and generally has an open frame structure 131. An example of a load handling device 130 incorporating the inventive concepts of the present invention is shown in FIGS. 16(a and b), with various modular sections 132(a and b) through 134(a and b) providing various functional features of the load handling device shown in FIGS. 17(a and b), and schematic diagrams of the various modular subframes that make up the load handling device shown in FIGS. 18(a and b). FIG. 18(a) is a simplified schematic diagram of a frame 131 supporting the major operating components of the load handling device, resulting from the assembly of modular subframes 132a, 133a, and 134a shown in FIG. 17(a). FIG. 18b is a more simplified diagram illustrating the building block 140 of the load handling device shown in FIG. 17a, resulting from the assembly of modular subframes 132b, 133b, and 134b shown in FIG. 17b. Each of the modular sections 132(a and b) through 134(a and b) is provided by a modular subframe that can be connected to form the frame 131 of the present invention. In a particular embodiment of the present invention, the frame 131 is configured as an open frame structure. However, the present invention is not limited to frames that are open frame structures; the frame may optionally include external cladding attached to the exterior of the frame. In the description of the present invention, the frame of the particular embodiment shown in FIGS. 16(a and b) will be described as an open frame structure.

[0074] As can be seen in the exploded view of one side of the load handling device shown in Figure 23, the various modular sub-frames 132c, 133c, 134c of the load handling device include connection points 142 at the corners of the modules 132c, 133c, and 134c to enable the various modular sub-frames 132c, 133c, 134c to be vertically stacked. In the particular embodiment of the invention shown in Figures 17(a and b) and 18(a and b), three modular sections 132(a, b, c), 133(a, b, c), and 134(a, b, c) are shown that are connectable in a vertical stack to form a hierarchical modular system. Starting from the bottom modular section 132(a, b, c) and proceeding upward, the three modular sections are referred to in this description as the first modular section 132(a, b, c), the second modular section 133(a, b, c), and the third modular section 134(a, b, c), each formed by a respective modular subframe. The three modular sections provide various functional features of the load handling device. In certain embodiments of the present invention, various functional features of the load handling device may be shared among one or more of the modular sections 132(a, b, c), 133(a, b, c), and 134(a, b, c) of the load handling device 130. For example, a wheel positioning mechanism and a wheel drive assembly may be shared among two or more modular sections of the load handling device. The number of modular sections is not limited to three, and various functional features of the load handling device may be divided among any number of modular sections.

[0075] Various functional features of the load handling device include, but are not limited to, a wheel assembly that enables movement of the load handling device on a grid structure or track, a wheel drive assembly that drives the wheel assembly that enables the load handling device to move on the grid structure, a wheel positioning mechanism, also known as a turning mechanism, a container lifting mechanism that picks up and lowers storage containers from grid cells of the grid framework structure, and electrical or electronic components of the load handling device.

[0076] As shown in FIGS. 16(a) and 16(b), the wheel assembly includes a pair of wheels 135 at the front of the load handling device 130 and a pair of wheels at the rear of the load handling device. For ease of explanation, the wheel assembly includes a pair of wheels 135 at the front of the load handling device and a pair of wheels at the rear of the load handling device, which will be referred to as a first set of wheels 135. The first set of wheels 135 are oriented to allow the load handling device to move in a first direction, i.e., the Cartesian X direction. To allow the load handling device to move in both the X and Y directions on the grid structure for movement in a second direction, i.e., the Cartesian Y direction, which is substantially orthogonal to the first direction as well as the first direction, the wheel assembly includes a pair of wheels 136 on either side of the load handling device, which will be referred to as a second set of wheels 136 for ease of explanation. Thus, to move in a first direction on the grid structure, the first set of wheels 135 engages with the grid structure and the second set of wheels 136 disengages from the grid structure. Similarly, to move in a second direction, a first set of wheels 135 disengages from the grid structure and a second set of wheels 136 engages the grid structure. The wheels are rotatably mounted to the open frame structure 131 via one or more wheel mounts 139, 141 (see Figures 18a and 22) and are configured to engage the grid structure to allow the load handling device to move in both the X and Y directions along the grid structure.

[0077] As described above, the electrical components may optionally include a control unit or controller 144a for controlling the operation of the wheel drive assembly, the wheel positioning mechanism, and the lifting drive mechanism of the container lifting mechanism. Typically, the wheel drive assembly, the wheel positioning mechanism, and the drive mechanism of the container lifting mechanism include one or more electric motors. Other electrical components of the load handling device include, but are not limited to, a communications module for receiving commands from an external central control system. The communications module includes a receiver that receives commands from the external control unit via a base station and a transmitter that transmits signals via an antenna 145 comprising data related to the positioning and / or status of the load handling device on the grid structure. The controller 144a, in communication with the communications module, controls the movement of the load handling device on the grid structure in response to receiving commands from the external central control system.

[0078] In the example of the robotic load-handling device shown in FIGS. 16(a and 16b), the load-handling device 130 further includes a receptacle 138 (see FIG. 16b) that functions as a battery chute within the open frame structure 131 for accommodating the power supply 138b. In other words, the receptacle 138 is "embedded" within the open frame structure 131 such that the receptacle 138 extends vertically through at least one of the modular subframes 132, 133, 134 of the open frame structure 131. By definition, the term "extending vertically through" also encompasses extending vertically through a horizontal plane that includes at least one of the modular subframes. The receptacle 138 provides a separate area within the open frame structure for lowering the power supply 138b into the open frame structure without colliding with other components of the load-handling device. While the receptacle is shown as having a cubic shape, it may have other shapes, such as a cylindrical shape, depending largely on the shape of the power supply or its casing. The top end of the receptacle is open and accessible from above the exterior of the loading device so that a power source can be lowered into the receptacle. The receptacle 138 includes one or more electrical connectors or charge-receiving elements configured to electrically couple to the charge-providing element of the power source. The charge-receiving elements are configured to connect to the charge-providing element of the power source when the power source is vertically received in the receptacle and to disconnect when the power source is vertically removed from the receptacle.

[0079] In detail, each modular section can be imagined as a rectangular open frame or rectangular modular subframe formed by connecting or interlocking corner brackets (see FIGS. 18(a) and 18(b)), where each corner bracket is shown as a connecting block in FIG. 18(b). A modular section is constructed by connecting adjacent connecting blocks in the same horizontal plane by one or more connecting elements 187 to form an open rectangular frame or modular subframe 186. Thus, vertically adjacent rectangular modular subframes or modular subframes 186 are connected by connecting vertically adjacent connecting blocks 140 as shown in FIGS. 17(a) and 17(b) to form an open frame structure 131. An example of a connecting block 140 is a corner bracket. In one modular section, each connecting block is connected to two other connecting blocks in the same horizontal plane by one or more connecting elements 184. The connecting elements can be connecting rods or tubes for connecting adjacent connecting blocks (corner brackets) within a single modular section. The connecting rods can be solid or hollow, depending on the connection with the connection blocks as described above. In a particular embodiment of the invention, the open frame structure is a three-dimensional structure defining a volume having an upper portion comprising the receptacle 138 (see Figures 16(a and b)), the control unit 144a, and the spool 182 (a and b) carrying the lifting tether, and a lower portion comprising the container receiving space 137.

[0080] The structural integrity of the open-frame structure must be sufficient to support the various functional features of the load-handling device, as well as have sufficient bending stiffness when the load-handling device is in operation on the grid structure. A variety of materials can be used to fabricate the connecting rods or tubes, including, but not limited to, metals, polymers (e.g., plastics), ceramics, or combinations thereof. To reduce the weight of the load-handling device and provide the structural properties necessary to support the various functional components of the load-handling device, the connecting rods connecting adjacent connection blocks are optionally constructed of carbon fiber bonded with a polymer matrix (referred to as carbon fiber rods). The connecting rods are secured to the connection blocks by being received in sockets in the connection blocks and then glued to the connection blocks by injecting adhesive into the sockets through injection ports, as described above with reference to Figures 1 through 9.

[0081] In a simplified modular section, the connecting blocks 140 are corner brackets, and the modular section includes four corner brackets. Each of the four corner brackets is directly connected to two other corner brackets in the same horizontal plane to form a simple open rectangular frame or subframe, as shown in FIG. 17b. However, it is also possible for a corner bracket within a single modular section to be indirectly connected to two other corner brackets by one or more corner brackets intermediate the corner brackets of the rectangular frame. Thus, the term "connected" in connection with the corner brackets of each modular section can be broadly interpreted to mean directly and / or indirectly connected to two other corner brackets.

[0082] To construct a load-handling device according to the present invention, various modular sections can be linked together by simply connecting vertically adjacent rectangular modular subframes 186 via their respective connection blocks or corner brackets 140 with one or more vertical connecting elements 188 to form an open frame structure 131, as shown in the simplified open frame structure of FIGS. 17a and 17b. In other words, the same connection block or corner bracket that connects to two other connection blocks or corner brackets within a single modular section can be used to vertically connect adjacent rectangular modular subframes. The corner brackets of vertically adjacent rectangular subframes can be attached to the same vertical connecting element 188 at each corner of the open frame structure, so that the vertical connecting element extends through the corner brackets of multiple vertically adjacent rectangular modular subframes. As a result, each corner of the open frame structure shares the same, or common, vertical connecting element. To connect multiple rectangular subframes to the same vertical connecting element at each corner of the open frame structure via their respective corner brackets, sockets in the corner brackets (connecting blocks) intermediate or between the bottom and top rectangular modular subframes are through-holes so that vertical connecting elements extend through the corner brackets at each corner when connecting vertically adjacent rectangular subframes 186 (see the second modular section in FIG. 17a). This has the advantage that multiple rectangular subframes 186 can be connected vertically in a stack by simply attaching multiple rectangular subframes to the same vertical connecting element at each corner of the open frame structure to form a load-handling device as shown in FIGS. 17(a) and 17(b). This is evident in the schematic diagram of one side of an open frame structure shown in FIG. 23, which shows vertical connecting elements extending through multiple connecting blocks at the corners of the open frame structure.

[0083] Alternatively, separate vertical connecting elements can be used to connect vertically adjacent rectangular modular subframes at each corner of the open frame structure. The length of the vertical connecting elements connecting vertically adjacent rectangular modular subframes defines the height of the open frame structure. The connecting elements 188 connecting vertically adjacent rectangular modular subframes can be the same type as the connecting elements connecting adjacent corner brackets of a given modular subframe in a horizontal plane, or they can be different types. For example, the connecting elements 188 connecting vertically adjacent rectangular modular subframes can be connecting rods used to connect corner brackets within a single modular section. Alternatively, the connecting elements 188 connecting vertically adjacent rectangular modular subframes can be solid connecting rods, while the connecting elements connecting corner brackets of a given modular subframe in a horizontal plane can be hollow tubes. The connection of the corner brackets that make up the connecting block by the horizontal connecting rod 184 and the vertical connecting rod 188 is exemplified by the pre-assembly of the second modular section shown in Figure 19, which comprises the supports or rails 166 for the wheel positioning mechanism described above.

[0084] A similar process of connecting the connecting blocks with horizontal connecting elements applies to the assembly of the first and third modular sections. Each corner bracket or connecting block 140 includes one or more sockets 187 shaped to receive one or more connecting elements 184, 188 for connecting the connecting blocks to form a single modular section and for connecting vertically adjacent modular sections in a vertical stack. The arrows in FIG. 19 indicate the orientation of the connecting elements 184 when inserted into their respective sockets 187 in the connecting block or corner bracket 140, corresponding to the direction along the first axis of the respective socket. In the particular example shown in FIG. 19, one or more of the sockets in each of the connecting blocks 140 are blind holes, and one or more of the remaining sockets are through holes. The blind holes are for coupling each connecting block with two other connecting blocks in the same horizontal plane by connecting elements to form one modular subframe, and the through holes in each connecting block enable vertically adjacent modular subframes to be connected in a vertical stack by one or more of the substantially vertical connecting elements.

[0085] Adhesive is injected into the sockets to secure the connecting elements to their respective connecting blocks. As mentioned above, the cross-sectional dimensions of the sockets 187 of the connecting block 140 are slightly oversized to allow the orientation of the connecting rods 184, 188 to be adjusted relative to their respective connecting blocks 140. A plurality of radially extending fingers or fins disposed within the sockets at least confine the adhesive injected into the sockets when securing the connecting elements to the connecting blocks. This is particularly important when the connecting blocks are oriented in the frame such that the longitudinal axis of the socket is substantially vertical. This is because there is a risk that the adhesive injected into the sockets will pool at the bottom or be pulled out by gravity, especially if the socket mouth is facing downward. The plurality of fingers or fins distributed around the inner walls of the sockets act as a barrier to at least prevent the adhesive from pooling or pulling out before it hardens. To assist in aligning or properly orienting the connecting elements relative to their respective connecting blocks during assembly, a jig or fixture is used, as shown in Figures 24 and 25. Further details of the assembly of at least a portion of the frame within a jig or fixture of the robotic load handling device are provided below.

[0086] To simplify the configuration of the load handling device while accommodating various functional features of the load handling device, at least a portion of the functional components of the load handling device are integrated into the open frame structure 131 of the load handling device 130 in the sense that at least a portion of the functional components of the load handling device are integral with one or more of the rectangular frame or modular subframes of the load handling device. For example, at least a portion of the wheel assembly is integral with one or more rectangular modular subframes, at least a portion of the wheel drive assembly is integral with one or more rectangular modular subframes, at least a portion of the wheel positioning mechanism is integral with one or more rectangular modular subframes, and / or at least a portion of the container lifting mechanism is integral with one or more rectangular modular subframes.

[0087] To integrate at least a portion of the various functional features of the load handling device into one or more of the rectangular modular subframes that make up the open-frame structure of the load handling device, one or more of the connection blocks 140 of one or more of the rectangular subframes 186 are fabricated with the functional features of the load handling device in mind. To integrate the various functional features of the load handling device into one or more of the modular subframes, at least a portion of one or more of the functional components of the load handling device are integrated into one or more connection blocks of one or more of the rectangular modular subframes. For example, one or more of the connection blocks connecting the rectangular modular subframes may be integrally formed with one or more mounts for spools, pulleys, and / or motors rather than having separate mounts for attachment to the frame of the load handling device.

[0088] A variety of connecting blocks can be used to construct the various modular sections, and the choice of connecting block will depend largely on the various functional features of the load handling device. The shape of the connecting block will become more complex as the complexity of the functional features of the load handling device increases. Examples of various connecting blocks 140 (b to d) in simplified form forming corner brackets of an open frame structure are shown in Figures 20 to 22, which represent various corner brackets for assembling rectangular modular subframes of the various modular sections of the load handling device.

[0089] Various lightweight materials can be used in fabricating the connection blocks. Examples of lightweight materials include, but are not limited to, various lightweight metals, such as aluminum, or various polymeric materials, such as plastic materials, or composite materials (e.g., carbon fiber / polymer composites). Various methods can be used to fabricate the connection blocks. These include, but are not limited to, machining from a block, injection molding, or casting. However, as the complexity of the connector blocks increases, more advanced fabrication methods can be used, especially when at least a portion of the functional components of the load handling device are integrated with the connection blocks 140, 140(b-d). The use of additive manufacturing, such as 3D printing, allows for the fabrication of complex connection blocks, allowing at least a portion of the functional components of the load handling device to be integrally formed with one or more of the connection blocks. The use of additive manufacturing in fabricating the connection blocks, particularly the corner brackets, allows one or more of the connection blocks to be topology optimized to take into account the stresses the connection block will experience in an open-frame structure. Additionally, additive manufacturing also allows for multiple fingers or fins to be integrally formed with the connection blocks. This is because additive manufacturing or 3D printing can create complex shapes that are not possible with machining alone. This is especially true when the connection block is topology optimized, as the results tend to yield complex shapes to account for the various loading constraints that the connection block will be subjected to when applied to the open-frame structure of the load-handling device.

[0090] With regard to the various functional features of the load handling device, the wheels of the wheel assemblies are supported by a rectangular modular subframe 186 in the bottom or first modular section. To accommodate the wheels of the wheel assemblies, each of the connecting blocks in the bottom or first modular section is integrally formed with one or more wheel mounts 139, 141 for the first and second sets of wheels. In the particular embodiment of the invention shown in Figures 18a and 22, each of the connecting blocks in the bottom modular section is formed in two parts to accommodate two wheel mounts, i.e., first wheel mount 139 and second wheel mount 141. The first wheel mount 139 is configured to mount the wheels of the first set of wheels 135, and the second wheel mount 141 is configured to mount the wheels of the second set of wheels 136. (There are two wheel mounts for each of the four connecting blocks 140d, resulting in a total of eight wheels arranged to support the open frame structure of the load handling device and mounted on the four connecting blocks 140d.) In other words, each of the four connecting blocks 140d of the first or bottom modular section is integrally formed with two wheel mounts, namely the first wheel mount 139 and the second wheel mount 141. To accommodate two wheel mounts on one connecting block 140d, the two wheel mounts of a given connecting block are assembled substantially perpendicular to one another, with the first wheel mount 139 providing a mount for a wheel that moves the load handling device in a first direction and the second wheel mount 141 providing a mount for moving the load handling device in a substantially orthogonal direction (see FIG. 22). In the particular embodiment of the invention shown in FIG. 22, the first wheel mount 139 and the second wheel mount 141 of the connecting block include shafts or spigots 198 for rotatably mounting their respective wheels. The shafts or spigots 198 can be formed integrally with the connecting block as shown in FIG.

[0091] Each connection block for mounting a wheel of a wheel assembly is connected to two other connection blocks by one or more connection elements 184 to form a rectangular modular subframe. In the particular example of the invention shown in Figures 17a and 18a, each of the connection blocks 140d is connected to two other connection blocks in the same horizontal plane by two connection elements 184 that can be received in openings or sockets 187 in the connection blocks (see Figure 22). However, the number of connection elements 184 connecting adjacent connection blocks in the same horizontal plane to form a rectangular modular subframe of the first modular section comprising the wheel assemblies is not limited to two connection elements, but can be any number of connection elements that provides the required structural rigidity of the rectangular frame.

[0092] To drive the rotation of the first and second sets of wheels, at least a portion of the wheel drive assemblies described above can be integrated into one or more of the rectangular subframes of the open-frame structure of the load handling device. In a particular example of the present invention, each of the first and second sets of wheels is driven by one or more motors (not shown) via a drive belt assembly 143a described in PCT application PCT / EP2021 / 055372 in the name of Ocado innovation Limited, the details of which are incorporated herein by reference. In the particular embodiment shown in Figures 16(a and b), a drive belt assembly 143a is provided for each set of wheels and includes a drive belt pulley gear arrangement 143b that engages with the edges of a pair of wheels 135, 136 on one side of the load handling device. The rims of these wheel pairs include a plurality of gear teeth 147 that cooperate with a drive belt 146. The toothed drive belt 146 engages both of these wheels. The drive belt 146 is guided by a driven wheel 148 attached to the open frame structure 131 of the load handling device 130 and a tensioning wheel arrangement 150. The tensioning wheel arrangement 150 is movably attached to the open frame structure 131 by a spring (not shown) to keep the drive belt 146 tensioned and engaged with the wheels. A drive wheel 151 is provided and attached to the open frame structure 131 (see FIG. 23). The drive wheel 151 is driven by a pulley and gear arrangement 143b connected to the axle or drive shaft of a motor (shown in FIG. 23). Rotation of the drive wheel 151 by the motor drives a pair of wheels connected to the drive belt 146. A wheel drive assembly is provided for each pair of wheels in the first set of wheels 135 and the second set of wheels 136. Thus, each pair of wheels of the first set of wheels 135 is synchronously driven by a respective drive assembly to move the load handling device in the X direction on the grid structure.Similarly, each pair of wheels in the second set of wheels 136 is synchronously driven by a respective drive assembly to move the load handling device in the Y direction on the grid structure.

[0093] Mounts for the drive and driven wheels carrying the drive belts may be integrally formed with one or more of the connection blocks 140d (see FIGS. 21 and 22) of one or more of the rectangular subframes. For example, in the particular embodiment of the invention shown in FIG. 22, each of the corner brackets 140d comprising wheel mounts 139, 141 of the wheel assemblies further comprises mounts 200 for the driven wheels 148 of the drive belt assembly 143a such that the drive belt 146 travels around the periphery of the wheels 135, 136 attached to the corner bracket 140d and around the driven wheels 148 on the same corner bracket 140d (see FIGS. 16 and 22). Each corner bracket 140d is integrally formed with two wheel mounting bases 139, 141 of wheels that are oriented perpendicular to each other to cover the direction of travel of the load handling device on the grid structure, so that the mounting base 200 of each driven wheel can be formed integrally with each of the wheel mounting bases 139, 141 of the corner bracket 140d.

[0094] A drive pulley 151 for driving the rotation of a pair of wheels in the first or second set of wheels is attached to a corner bracket 140c of the rectangular modular subframe located higher in the vertical stack, such that a drive belt 146 extends around a pair of wheels on one side of the load handling device and around the drive wheel attached to the higher modular section (see FIG. 23). In a specific embodiment of the invention, the drive wheels for driving the drive belt of each wheel drive assembly are attached to a shaft or spigot 202 integrally formed with the corner bracket 140c that constitutes the rectangular modular subframe of the second modular section (see FIG. 21). As a result, each pair of wheels in the first and second sets of wheels is driven by a drive belt connecting a driven wheel in the first modular section 132a with a driven wheel attached to a corner bracket of the second modular section 133a. This is repeated for the other drive assemblies on each side of the load handling device, as shown in FIG. 16a. Also shown in Figure 16a is that each wheel drive assembly 143a that drives a pair of wheels further comprises the tensioning wheel arrangement 150 described above to ensure that the drive belt around a given pair of wheels remains taut. In the particular example of the load handling device shown in Figure 16, one or more of the corner brackets of the rectangular frame that supports the wheels also comprise a wheel tensioning arrangement.

[0095] The drive assembly is not limited to the drive belt assembly described above, and the connecting blocks of the rectangular modular subframe that carry the wheels of the wheel assemblies can be integrated with the mounting bases that carry the hub motors described above. Thus, each corner bracket of the rectangular modular subframe of the first or bottom modular section can be formed integrally with a mounting base for a drive assembly that includes a hub motor, the inner hub of the hub motor being attached to the corner bracket. Since each corner bracket of the first or bottom modular section is formed with two wheel mounting bases for mounting two wheels, each corner bracket is formed integrally with two mounting bases for mounting two hub motors, one for mounting a wheel that travels in a first direction and the other for mounting a wheel that travels in a second direction.

[0096] To change direction on the grid structure, the load handling device includes a wheel positioning mechanism. Various wheel positioning mechanisms are known in the art, some of which have been described above. Considering the need for sufficient force to lift a pair of wheels of a given wheel set vertically relative to the open-frame structure, at least a portion of the wheel positioning mechanism is attached to a rectangular subframe of the open-frame structure that is reinforced to support the weight of the wheel pairs on each side of the load handling device. In the specific example of the load handling device shown in Figures 16(a and b) and 19, the rectangular subframe of the second modular section is reinforced with one or more struts or braces 206 and is referred to as a "middle halo" because it is located substantially in the middle of the height of the load handling device, i.e., between the first and third modular subframes (see Figure 17a). Reinforcement of the middle halo is provided by one or more cross braces 206 extending across the rectangular modular subframe. The particular example of a wheel positioning mechanism shown in Figures 16 and 23 is based on a cam mechanism 152 taught in PCT / EP2022 / 073670, the details of which are incorporated herein by reference in their entirety. The cam mechanism 152 includes a cam 154, a cam follower 158 movable along the cam 154, a traveler 164 for moving the cam follower, and a cam motor 168 coupled to the traveler 164.

[0097] The traveler 164 is configured to move along a rail 166 on one side of the load handling device to lift a pair of wheels. The rail 166 supporting the traveler for lifting the pair of wheels includes a horizontal connection element 184 extending between the connection blocks of the rectangular modular subframe of the intermediate halo so that the traveler moves along the connection element 184 connecting the connection blocks 140 on one side of the load handling device. The connection element 184 supporting the traveler 164 of the intermediate halo thus functions as an overhead rail (see FIG. 19). In the specific example of the invention shown in FIG. 23, the traveler 164 is slidably attached to the connection element connecting the connection blocks in the same horizontal plane. This is repeated for the other pairs of wheels on each side of the load handling device. At least two connection elements 184 extend between the connection blocks 140 on one side of the load handling device to support the traveler. One or more inserts 208 are sandwiched between two connection elements 184 extending between the corner brackets 140 to provide flexural stiffness to the connection elements extending between the corner brackets 140 to prevent excessive bending of the connection elements as the traveler moves along the connection elements.

[0098] In a specific example of the present invention, the cam mechanism for each pair of wheels in the first and second sets of wheels is based on a double cam arrangement, and the traveler is configured to raise or lower a given pair of wheels via this double cam arrangement. The cams cooperating with the cam followers can be attached to or integrally formed with the connection blocks supporting the wheels of the wheel assemblies. As the cam followers advance along the cams, an upward or downward force is applied to the respective connection blocks carrying the wheels of the first or second sets of wheels, thereby raising or lowering that wheel depending on the direction of advancement of the load handling device on the grid structure. The cams 154 cooperating with the cam followers 158 can be integrally formed with the respective connection blocks 140d comprising the wheel mounts of the wheel assemblies, as shown in Figures 16(a and b) and 22. Two cams 154, one for each of the wheel mounts 139, 141, are shown integrally formed with the corner brackets 140e. As can be seen from the above description in conjunction with Figures 16 and 22, at least a portion of the wheel positioning mechanism is formed integrally with the connecting blocks of one or more rectangular modular subframes that make up the various modular sections of the load handling device.

[0099] In a particular embodiment of the invention, cam motor 168 is configured to move traveler 164 along one side of the load handling device by means of a cam belt 170 having one end affixed to cam motor 168 and the other end affixed to traveler 164. Cam belt 170 is wrapped around a cam spool attached to a drive shaft of cam motor 168 such that rotation of the cam spool by cam motor 168 exerts a pulling force on cam belt 170, thereby moving traveler 164, which is affixed to cam belt 170, along rail 166. To return traveler 164 to its initial position, a second motor can exert an opposing pulling force on traveler 164 to pull the traveler in the opposite direction.

[0100] FIG. 16a also shows that a cam motor 168 for moving the traveler along the connecting element is attached to a connection block 140c of a rectangular modular subframe that constitutes the open-frame intermediate halo. One or more mounting bases for one or more motors are integrally formed with the connection block of the rectangular frame of the intermediate halo, more specifically, with a corner bracket. As shown in FIG. 21, one or more openings 210 are integrally formed in the corner bracket 140c for receiving the motor shaft of the motor. The corner bracket 140c also supports a spool that winds the cam belt when the spool rotates, so that the cam belt is wound onto the spool when the cam motor 168 rotates clockwise and unwound from the spool when the cam motor 168 rotates counterclockwise. Clockwise and counterclockwise rotation of the spool moves the traveler along the cam to raise and lower the pair of wheels, respectively.

[0101] In addition to at least a portion of the wheel positioning mechanism being integrally formed with the connecting blocks or corner brackets that make up the rectangular subframe of one or more modular sections, at least a portion of the container lifting mechanism, and more particularly, the winch assembly, can also be integrally formed with the rectangular frame of one or more modular sections. The container lifting mechanism includes first and second lifting shafts 183 (a and b) for driving the rotation of four spools carrying lifting tethers connected to the grabber devices. The grabber device 172 shown in FIG. 15 includes four locating or guide pins 174 near or at each corner of the grabber device 172 that mate with corresponding notches or holes formed in the four corners of the container 10, and four gripper elements 176 arranged on the bottom side of the grabber device 172 to engage the rim of the container. The locating pins 174 help properly align the gripper elements 176 with the corresponding holes in the rim of the container. Each of the gripper elements 176 includes a pair of wings 178 foldable to be received within a corresponding hole in the rim of a container and in an open, deployed configuration that is larger in at least one dimension than the hole in the rim of the container so as to lock onto the container. The wings 178 can be driven to the open configuration by a drive gear. More specifically, the head of at least one of the wings includes a plurality of teeth that mesh with the drive gear such that, when the gripper elements 176 are actuated, rotation of the drive gear rotates the pair of wings from the folded configuration to the open, deployed configuration. When in the folded, or closed, configuration, the gripper elements 176 are sized to be received within a corresponding hole in the rim of a container. The foot of each wing of the pair of wings includes a stopper 180, e.g., a boss, that, when received within a corresponding hole in the rim of a container, engages with the underside of the rim when in the deployed configuration and locks onto the container when the grabber device 172 is rolled upward toward the container-receiving portion of the material handling device.

[0102] First and second lift shafts 183(a and b) are rotatably mounted to the rectangular subframes of the modular sections. In the example shown in FIG. 17a, the first and second lift shafts 183(a and b) are rotatably mounted to the rectangular subframes of the third modular sections 134a, b, c. FIGS. 17a and 18a show the first and second lift shafts 183(a and b) extending across the rectangular modular subframes. The first and second lift shafts are substantially parallel and spaced apart to define spaces for receiving the receptacles 138. The ends of the first and second lift shafts are shown rotatably mounted to respective connection blocks 140b through connecting block shaft openings 212, as shown in FIG. 20. The connecting block shaft openings 212 are sized to rotatably receive the ends of the lift shafts 183(a and b). Bearings may be installed in the shaft openings 212 for mounting on the ends of the lift shafts 183(a and b).

[0103] In a specific embodiment of the present invention, the container-receiving space 137 (see FIG. 18a) for receiving the storage container when lifted by the grabber device is accommodated within the open frame structure of the load handling device, more specifically, within the area of ​​the first, second, and third modular sections (the third modular section supports a spool carrying the lifting tether). However, when vertically adjacent modular sections are connected via vertical connection elements by their respective connection blocks, it is necessary for the grabber device to be guided to prevent jamming of the connection block when it is lifted and lowered into and out of the container-receiving space. In a specific embodiment of the present invention, downwardly extending guides (not shown) are attached to the connection block 140c of the second modular section of the load handling device, one at each corner of the rectangular frame, to guide the grabber device when it is lowered or lifted into the container-receiving space 137. Each of the guides extends downward within the interior of the container-receiving space and is shaped to include two orthogonal guide plates to accommodate the corners of the grabber device shown in FIG. 15.

[0104] Since the container lifting mechanism is configured to lift and lower storage containers that may weigh up to 40 kg, the connecting elements extending between the corner brackets can be braced with one or more bracing elements 206 to strengthen the rectangular frame of the modular section that supports the spools that carry the lifting tethers.

[0105] Fabrication of the load-handling device frame involves separately constructing various modular subframes 186 by inserting connection ends of connection elements into openings or sockets 187 of appropriate connection blocks, as shown in FIGS. 20-22, to provide various functional features of the load-handling device. A typical modular subframe includes at least four connection blocks, with each of the at least four connection blocks of a single modular subframe connected to two other connection blocks by one or more of the connection elements to form a substantially rectangular frame. Once the separate modular subframes have been assembled to provide the various functional features of the load-handling device described above, vertically adjacent modular subframes are connected in a stack by one or more vertical connection elements to form a frame or frame structure. To help reduce the weight of the load-handling device according to the present invention, the connection elements are typically hollow, such as hollow pipes. A similar assembly process can be used to create the receptacles 138. A jig can be used to assemble the individual rectangular modular subframes. The connections between the connecting blocks and the connecting elements are fixed on site in a jig by injecting adhesive through respective inlets into the sockets of the connecting blocks. As it is important that the frame formed by the assembly of the connecting elements and the connecting blocks meets the required tolerances in terms of dimensions and / or size, it is necessary that adjustments can be made to the connecting elements.

[0106] 24 and 25 are examples of a jig or fixture 214 for pre-assembling at least a portion of the open frame structure 131 of the robotic load handling device 130 before the pre-assembled portions are assembled into a modular subframe. The pre-assembled portions shown in FIGS. 24 and 25 represent a connection or linkage between two connection blocks 140d on one side of the open frame structure. The jig or fixture 214 includes a mounting platform 216 and one or more clamps 218 for securing the connection blocks 140d to the mounting platform at predetermined orientations and separations relative to each other. In the particular example shown in FIGS. 24 and 25, the connection blocks 140d correspond to the wheel mounts 139, 141 described above with reference to FIG. 22.

[0107] One or more guides 220 are used to guide the connecting element 184 into a predetermined orientation within the connecting block so that the pre-assembled parts have predetermined tolerances in terms of size and shape. The guides 220 can include one or more reference points used to guide the connecting element into the correct orientation within the connecting block. The default position is one in which multiple fingers within the socket of the connecting block guide the connecting end of the connecting element 184 toward the center of the socket so that the longitudinal axes of both the connecting element and the socket are concentric. The ability of the radially extending fingers to elastically deform within the socket allows the orientation of the connecting element 184 to be adjusted relative to the connecting block 140d. Various adjustments possible for the connecting element relative to the connecting block were discussed above with reference to Figures 7(a) through 7(d) and include (a) angle, (b) eccentricity, (c) ovality, and (d) a combination of angle and ovality.

[0108] Once the connecting blocks and connecting elements are pre-assembled in the jig or fixture 214 and the pre-assembled portions are adjusted as necessary to fit within predetermined size and / or shape tolerances, the connecting elements are secured in place in their respective connecting blocks to prevent further movement when the pre-assembled portions are released from the jig or fixture. While the pre-assembled portions are clamped in the jig or fixture, adhesive is injected into the sockets of the connecting blocks through their respective injection ports in the field. As described above with reference to FIGS. 1 and 2 , injection ports with openings on the exterior of the connecting blocks allow adhesive to be injected into the sockets in the field while the pre-assembled portions are clamped in the jig or fixture. The amount of adhesive injected into the sockets can be determined by the presence of adhesive emerging from the release or exhaust holes. The presence of adhesive in the release holes indicates that the adhesive has sufficiently filled the glue channel defined by the space between the exterior surface of the connecting end of the connecting element and the interior wall of the socket. As described above, one or more sets of fingers can be used to control the size of the glue channel and, therefore, the adhesive coverage on the connection ends of the connection elements in the socket. The cross-sectional dimensions of the outlet lumen of the discharge hole can be varied to prevent excess adhesive from escaping through the discharge hole; i.e., a portion of the outlet lumen is enlarged to capture any excess adhesive that overflows from the socket. Once adhesive is injected into the required inlets of the connecting blocks to secure the connecting blocks to their respective connection elements while the pre-assembled sections are clamped to the jig or fixture, the adhesive is allowed to cure before the pre-assembled sections are removed from the jig or fixture. The pre-assembled sections shown in FIGS. 24 and 25 represent a portion of the frame structure of a robotic load-handling device. In the particular example shown in FIGS. 24 and 25, the pre-assembled sections represent one side of a modular subframe, i.e., a first modular subsection 132(a, b, c), including wheel mounts 139, 141 for mounting a pair of wheels and a cam mechanism 152.This is repeated for the other three sides of the first modular subframe, making up a total of four sides of the rectangular modular subframe as shown in Figure 17a. Each of the four sides carries a pair of wheels of the wheel assembly. The pre-assembled sections are held in a rectangular array by vertical connecting elements to allow each of the four sides carrying a pair of wheels to move independently of each other to turn on the grid structure.

[0109] The process of pre-assembling various portions of the frame structure is repeated for the other modular sections of the frame. In the case of second modular section 133 and third modular section 134, the pre-assembled portions comprise four connection blocks arranged as rectangular subframes by one or more horizontal connection elements. Vertically adjacent modular subframes are connected in a vertical stack by one or more vertical connection elements to form the frame as shown in FIG. 17a. Various jigs or fixtures can be used to pre-assemble the various modular sections of the frame to achieve various functional features of the robotic load handling device.

Claims

1. A connection block comprising: i) a socket for receiving a connecting end of a connecting element along a first axis, said socket having an inner wall; ii) a plurality of fingers resiliently biased to extend substantially radially inwardly from the inner wall of the socket to follow the connecting end of the connecting element when the connecting end is received in the socket in use, the fingers being spatially distributed around the inner wall of the socket to define a guide for guiding the connecting end of the connecting element towards a center of the socket; iii) an inlet having an inlet lumen extending along a second axis from an opening in the exterior of the connecting block to an opening in the interior wall of the socket for injecting adhesive into the socket; A connection block comprising:

2. The connecting block of claim 1 , wherein the first axis and the second axis form an acute or obtuse angle.

3. 3. The connecting block of claim 1, wherein the first axis is substantially perpendicular to the second axis.

4. 4. The connecting block of claim 1, wherein the first axis intersects the second axis.

5. 5. A connection block according to claim 1, wherein the fingers are spaced around the inner wall of the socket.

6. 6. The connecting block of claim 5, wherein the spacing between adjacent fingers is in the range of 0.1 mm to 1 mm.

7. 7. The connecting block of claim 1, wherein the plurality of fingers comprises a plurality of fins arranged such that each fin at least partially overlaps an adjacent fin.

8. 8. The connecting block of claim 1, further comprising an outlet comprising an outlet lumen extending along a third axis from an opening in the interior wall of the socket to an outlet opening on the exterior of the connecting block for discharging fluid from the socket.

9. The connecting block of claim 8 , wherein the third axis and the first axis form an acute or obtuse angle.

10. 10. The connecting block according to claim 8 or 9, wherein the third axis is substantially perpendicular to the first axis or the second axis.

11. 11. The connecting block of claim 8, wherein the third axis intersects the first axis.

12. 12. A connecting block according to any one of claims 7 to 11, wherein at least a portion of the outlet lumen has a cross-sectional diameter in the range of 0.5 mm to 2 mm.

13. 13. A connecting block according to any one of claims 7 to 12, wherein the outlet lumen comprises a first portion having a first cross-sectional dimension and a second portion having a second cross-sectional dimension, the second cross-sectional dimension being different from the first cross-sectional dimension.

14. The connecting block of claim 13 , wherein the first cross-sectional dimension is smaller than the second cross-sectional dimension.

15. 15. A connecting block according to any one of claims 1 to 14, wherein each of the plurality of fingers is inclined at an angle in the range of 5° to 90° relative to the inner wall of the socket.

16. The connecting block of claim 15, wherein the angle is an acute angle.

17. 17. A connecting block according to claim 1, wherein each of the plurality of fingers comprises a first end hinged to the inner wall of the socket by a flexible joint, and a second end, the second end being a free end.

18. 18. The connecting block of claim 17, wherein the second end is tapered.

19. 19. A connecting block according to claim 17 or 18, wherein the inner wall comprises a recess adjacent the first end of each of the plurality of fingers to allow each of the plurality of fingers to rotate about the first end.

20. 20. A connecting block according to claim 1, wherein the plurality of fingers are arranged around the periphery of the inner wall of the socket so as to surround the connecting end of the connecting element when the connecting end of the connecting element is inserted into the socket.

21. 21. The connecting block of claim 20, wherein the plurality of fingers are arranged to form an opening concentric with the opening in the socket.

22. 22. The connecting block of any one of claims 1 to 21, wherein at least a portion of each of the plurality of fingers is constructed from a compliant material.

23. 23. A connecting block according to any one of claims 1 to 22, wherein the plurality of fingers comprises a first set of fingers and a second set of fingers, each of the first set of fingers and the second set of fingers comprising the plurality of fingers according to any one of claims 1 to 22.

24. 24. The connecting block of claim 23, wherein the first set of fingers are spaced axially along a longitudinal axis of the socket from the second set of fingers to define a glue channel between the first set of fingers and the second set of fingers.

25. 25. A connecting block according to claim 23 or 24, wherein the inlet is located between the first set of fingers and the second set of fingers.

26. 26. A connecting block according to any one of claims 1 to 25, wherein the sockets are blind holes or through holes.

27. 27. A connecting block according to any one of the preceding claims, comprising a plurality of sockets, the first axes of each of the plurality of sockets forming an acute or obtuse angle with each other.

28. 28. The connecting block of claim 27, wherein the first axes of each of the plurality of sockets are orthogonal to one another.

29. 29. The connecting block of any one of claims 1 to 28, wherein the plurality of fingers are integrally formed with the connecting block.

30. A joint, i) a connection block according to any one of claims 1 to 29; ii) a connection element receivable in the socket of the connection block; A joint comprising:

31. 31. The joint of claim 30, wherein the connecting element comprises a tube or a rod.

32. 1. A robotic material handling device for lifting and moving one or more stackable containers in an inbound and outbound system, the inbound and outbound system comprising a grid structure comprising a plurality of grid members, the grid members comprising a first set of grid members and a second set of grid members, the second set of grid members being substantially orthogonal to the first set of grid members such that the plurality of grid members are arranged in a grid pattern to guide movement of the material handling device on the grid structure, the material handling device: a) a container lifting mechanism comprising a container gripping assembly configured to releasably grip a container, and a lifting drive mechanism configured to raise and lower the container gripping assembly; b) a wheel assembly comprising a first set of wheels engaging the first set of grid members to guide movement of the load handling device in a first direction, and a second set of wheels engaging the second set of grid members to guide movement of the load handling device in a second direction, wherein the second direction is transverse to the first direction; c) a wheel positioning mechanism configured to selectively lower or raise the first set of wheels or the second set of wheels into engagement or disengagement with the first set of grid members or the second set of grid members; a frame for supporting the 30. A robotic load handling device, wherein the frame comprises a plurality of modular subframes arranged in a vertical stack, at least one of the plurality of modular subframes comprising at least one connection block according to any one of claims 1 to 29 and a connection element receivable in the socket of the at least one connection block.

33. 33. The robotic material handling device of claim 32, wherein the frame further supports a receptacle for accommodating a power source, the receptacle having an externally accessible open top end for receiving the power source in a substantially vertical orientation, and comprising a charge-receiving element for electrically coupling with a charge-providing element of the power source to provide power to the wheel positioning mechanism and the container lifting mechanism.

34. 34. A robotic load handling device as described in claim 32 or 33, wherein the at least one of the plurality of modular subframes comprises at least four connection blocks, each of the at least four connection blocks of each modular subframe connected to two other connection blocks by a plurality of connection elements to form a rectangular modular subframe.

35. 35. The robotic load handling device of claim 34, wherein each of the plurality of modular subframes comprises at least four connection blocks, each of the at least four connection blocks of each modular subframe connected to two other connection blocks by a plurality of connection elements to form a rectangular modular subframe, and wherein the connection blocks of vertically adjacent modular subframes are connected by connection elements.

36. 36. The robotic cargo handling device of any one of claims 32 to 35, wherein the at least one connection block comprises at least a portion of the container lifting mechanism, and / or the wheel assembly, and / or the wheel positioning mechanism, and / or electrical components.

37. 37. The robotic cargo handling device of claim 36, wherein the container lifting mechanism, and / or the wheel assembly, and / or the wheel positioning mechanism, and / or the at least a portion of the electrical components are integrally formed with at least one connection block.

38. An automated storage and retrieval system, a grid structure comprising a plurality of grid members, the grid members comprising a first set of grid members and a second set of grid members, the second set of grid members being substantially orthogonal to the first set of grid members such that the plurality of grid members are arranged in a grid pattern to guide movement of one or more load handling devices operating on the grid structure; At least one robotic load handling device according to any one of claims 32 to 37 operable on the grid structure; An automated storage and retrieval system.

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