Method, system, and computer program for controlling an automated storage and retrieval system during reconstruction of its physical design

Abstract

A method, system, and computer program for controlling the operation of an automated storage and retrieval system (1) during the reconfiguration of its physical design, the method including a planning and design phase, in which a new design is established and storage columns (105) with rail systems (108) affected by the reconfiguration are excluded from the selection of available routes for container handling vehicles (201) operating on the storage system (1), a transfer phase, in which storage containers (201) located in the excluded storage columns (105) are transferred to other storage columns (105), a rerouting phase, in which traffic flow of container handling vehicles (201) is rerouted according to available routes and a master controller (220) is instructed to control the vehicles (201) according to the available routes, and a reconfiguration phase.

Description

Technical Field

[0001] The present invention relates to an automatic storage and retrieval system for storing and retrieving containers handled by a container handling vehicle, and more specifically, to a method, a system, and a computer program for controlling the operation of an automatic storage and retrieval system whose physical design is being reconstructed.

Background Art

[0002] FIG. 1 discloses a typical prior art automatic storage and retrieval system 1, which has a skeletal structure 100 and a container handling vehicle 201 operating on such a system 1.

[0003] The skeletal structure 100 includes upright members 102, horizontal members 103, and a storage volume, and the storage volume includes storage columns 105 arranged in rows between the upright members 102 and the horizontal members 103. In these storage columns 105, storage containers 106, also known as bins, are stacked on top of each other to form a stack 107. The members 102, 103 can typically be made of metal, for example, extruded aluminum profiles.

[0004] The skeletal structure 100 of the automatic storage and retrieval system 1 includes a rail system 108 arranged across the upper part of the skeletal structure 100, and on that rail system 108, a plurality of container handling vehicles 201 are operated to lift the storage containers 106 from the storage columns 105, lower the storage containers 106 into it, and transport the storage containers 106 above the storage columns 105.

[0005] The rail system 108 includes a first set of parallel rails 110 arranged to guide the movement of the container handling vehicle 201 in a first direction X across the upper part of the frame structure 100, and a second set of parallel rails 111 arranged at right angles to the first set of rails 110 for guiding the movement of the container handling vehicle 201 in a second direction Y that is perpendicular to the first direction X. The first rail 110a in the first direction X, the second rail 110b in the first direction X, the first rail 111a in the second direction Y, and the second rail 111b in the second direction Y are also shown in FIG. 1.

[0006] The storage container 106 is stored within a column 105 that defines a third direction Z perpendicular to the first direction X and the second direction Y. The storage container 106 is accessed by the container handling vehicle 201 through an access opening 112 within the rail system 108, i.e., the rail system 108 is disposed on the skeletal structure 100 so as to define the perimeter of each access opening 112 above each storage column 105.

[0007] The container handling vehicle 201 can move laterally above the storage column 105, i.e., move within a plane parallel to the horizontal X - Y plane. The storage container is stored within the storage column 105.

[0008] The upright members 102 of the skeletal structure 100 can be used to guide the storage container during the raising of the container out of and the lowering of the container into the column 105. The stack 107 of containers 106 is typically self - supporting.

[0009] Z = 1 identifies the top layer of the storage container, i.e., the layer directly below the rail system 108, Z = 2 identifies the second layer below the rail system 108, Z = 3 identifies the third layer, and so on. In the exemplary prior art disclosed in FIG. 1, Z = 8 identifies the bottommost layer of the storage container. Similarly, X = 1 ··· n and Y = 1 ··· n identify the positions of each storage column 105 in the horizontal plane. As a result, for example, using the Cartesian coordinate system X, Y, Z shown in FIG. 1, it can be said that the storage container identified as 106’ in FIG. 1 occupies the storage position X = 10, Y = 2, Z = 3. The container handling vehicle 201 can be said to travel within the layer Z = 0, and each storage column 105 can be identified by its X and Y coordinates.

[0010] The storage volume of the skeletal structure 100 is often referred to as a grid 104, and the possible storage positions within the storage columns 105 in this grid are referred to as storage cells. Each storage column 105 can be identified by its position in the X and Y directions, while each storage cell can be identified by a container number in the X, Y, and Z directions.

[0011] The rail system 108 typically comprises rails with grooves, and the wheels of the storage container vehicle 201 can run in those grooves. Alternatively, the rails can comprise elements protruding upwards, and the wheels of the vehicle are provided with flanges to prevent derailment. These grooves and upwards protruding elements are collectively known as a track. Each rail can comprise one track, or each rail can comprise two parallel tracks.

[0012] WO 2018146304 (the content of which is incorporated herein by reference) illustrates an exemplary configuration of a rail system 108 comprising rails and parallel tracks in both the X and Y directions.

[0013] In the skeletal structure 100, most of the columns 105 are storage columns 105, that is, the columns 105 where the storage containers 106 are stored in the stack 107. However, some columns 105 may have other purposes. In FIG. 1, columns 119 and 120 are such special-purpose columns and are used by the container handling vehicle 201 for unloading and / or loading the storage container 106 so that the storage container 106 can be transported to an access station (not shown). At the access station, the storage container 106 can be accessed from the outside of the skeletal structure 100 or transferred outside or into the skeletal structure 100. In the art, such a location is usually referred to as a "port", and the columns where the ports are located can be referred to as "port columns" 119, 120. The transport to the access station can be in any direction, horizontal, diagonal, and / or vertical. For example, the storage container 106 is installed randomly within the skeletal structure 100 or in a dedicated column 105 and then loaded by any container handling vehicle 201 and transported to the port columns 119, 120 for further transport to the access station. Note that the term "diagonal" means the transport of the storage container 106 having a general transport direction at a location between horizontal and vertical.

[0014] In FIG. 1, the first port column 119 can be, for example, a dedicated unloading port column where the container handling vehicle 201 can unload the storage container 106 to be transported to the access or transfer station, and the second port column 120 can be a dedicated loading port column where the container handling vehicle 201 can load the storage container 106 transported from the access or transfer station.

[0015] The access station can typically be a picking station or a storage station, where product items are removed from or positioned within the storage container 106. At the picking or storage station, the storage container 106 is usually not removed from the automated storage and retrieval system 1 but is returned back into the framework structure 100 when accessed. Ports can also be used to transfer the storage container to another storage facility (e.g., another framework structure or another automated storage and retrieval system), to a transport vehicle (e.g., a train or a large truck), or to a production facility.

[0016] When a storage container 106 stored within one of the columns 105 disclosed in FIG. 1 is to be accessed, one of the container handling vehicles 201 is instructed to retrieve the target storage container 106 from its location and transport it to the unloading port column 119. This operation involves moving the container handling vehicle 201 to a location above the storage column 105 where the target storage container 106 is positioned, using a lifting device (not shown) of the container handling vehicle 201 to retrieve the storage container 106 from the storage column 105, and transporting the storage container 106 to the unloading port column 119. If the target storage container 106 is located deep within the stack 107, i.e., with one or more other storage containers 106 positioned above the target storage container 106, the operation also involves temporarily moving the storage containers positioned above prior to lifting the target storage container 106 from the storage column 105. Sometimes, this step, which is sometimes referred to in the art as "mining," can be performed using the same container handling vehicle 201 that is subsequently used to transport the target storage container to the unloading port column 119, or using one or more other cooperating container handling vehicles 201. Alternatively, or in addition, the automated storage and retrieval system 1 can have a container handling vehicle 201 dedicated specifically to the task of temporarily removing storage containers from the storage columns 105. Once the target storage container 106 has been removed from the storage column 105, the temporarily removed storage container 106 can be repositioned back into the original storage column 105. However, the removed storage container 106 can alternatively be transferred to another storage column 105.

[0017] When storage container 106 is to be stored in one of columns 105, one of the container handling vehicles 201 is instructed to load storage container 106 from loading port column 120 and transport it to a location above the storage column 105 in which it is to be stored. After any storage container positioned at or above the target position within storage column stack 107 is removed, container handling vehicle 201 positions storage container 106 at the desired location. The removed storage container can then be lowered back into storage column 105 or transferred to another storage column.

[0018] To monitor and control automated storage and retrieval system 1, for example, so that a desired storage container 106 can be delivered to a desired location at a desired time without the container handling vehicles 201 colliding with each other, automated storage and retrieval system 1 includes a control system 500 for tracking storage containers 106, and control system 500 is typically computerized and typically includes a database.

[0019] If the automated storage and retrieval system 1 described above is to be modified by reconstructing it, the rail system 108 can typically be affected when storage columns 105 and / or port columns 119, 120 are added and / or removed. For example, when a storage column 105 with an associated rail system 108 is added, the existing rail system on the adjacent storage column to which it is to be connected can be affected and cannot be used during reconstruction. Similarly, if a storage column 105 within rail system 108 is removed, the rail system on the adjacent storage column to which it is to be connected can be affected and cannot be used.

[0020] This means that several previously available routes for the container handling vehicle 201 running on the rail system are no longer available, thereby meaning that downtime is necessary by temporarily shutting down the automated storage and retrieval system 1 until the reconstruction of the system 1 is completed.

[0021] However, downtime of the system 1 can be expensive for the operator and is thus undesirable. The present invention addresses and solves this problem by a method and a system for controlling the automated storage and retrieval system 1 such that it normally operates in at least a zone that is not affected by the reconstruction of the system.

Prior Art Documents

Patent Documents

[0022]

Patent Document 1

Summary of the Invention

Means for Solving the Problems

[0023] The present invention is defined by a method for controlling an automated storage and retrieval system during its physical design reconstruction. The storage and retrieval system comprises a skeletal structure forming a three-dimensional storage grid structure for storing storage containers, the grid structure forming vertical storage columns each having the same horizontal area defined by the size of the access openings of the vertical storage columns, a rail system being arranged on the skeletal structure defining around each access opening above each storage column, the rail system providing a path available for a container handling vehicle for storing storage containers into and retrieving them from the storage columns, each vehicle comprising a vehicle controller communicating with a master controller. The master controller handles and transfers storage containers and assigns work to each vehicle for controlling the traffic flow of the vehicles according to a routing planner. The master controller and / or the routing planner are connected to a database comprising layout information of the rail system and location information of the vehicles and storage containers. The routing planner determines an optimal path on the rail system for each vehicle based on the available paths according to the layout information of the rail system and the location information of each vehicle and storage container. The method comprises the following steps. - After a design step, a new physical design of the skeleton and the corresponding rail system is designed, and designed such that a part of the rail system is a buffer zone, the rail system being able to be affected by the reconstruction, a part of the rail system being to be removed from the automated storage and retrieval system, the step comprising updating the database with layout information with the new physical design and the rail system affected by the reconstruction. - A transfer step, in which the storage container has a storage position in storage in the column below a part of the rail system within the buffer zone and the part of the rail system to be removed is transferred. - A temporary route designation step, wherein the database updates the layout information of the rail system, excludes the part of the rail system within the buffer zone and the part of the rail system to be removed from the available routes, the route designation planner re-routes the traffic flow of the container handling vehicle according to the available routes not affected by the reconstruction, and the master controller is commanded by the route designation planner to control the vehicle according to the available routes; - After the reconstruction step, the automated storage and retrieval system is reconstructed according to the new physical design by adding and / or removing parts of the framework and the rail system. A final route designation step, wherein the layout information of the rail system in the database is updated to include a part of the rail system within the buffer zone and the new part of the rail system being constructed within the available routes, and the route designation planner designates the traffic flow of the vehicles on the rail system using the updated layout information after the reconstruction of the physical design of the automated storage and retrieval system.

[0024] According to an embodiment, the buffer zone is defined as a storage column and the corresponding rail system adjacent to the storage column to be removed or added during reconstruction. The buffer zone functions as a boundary between a part of the rail system that can be used and a part of the rail system that cannot be used during the reconstruction process.

[0025] According to an embodiment, the storage containers are transferred by moving the storage containers to storage columns not affected by the reconstruction and / or locations outside the storage and retrieval system. In this way, the storage containers within the storage columns affected by the reconstruction will be accessible after the buffer zone is established.

[0026] According to an embodiment, the location information in the database is updated with the new storage locations of the transferred storage containers.

[0027] According to an embodiment, access to the buffer zone is physically blocked by installing a barrier on a part of the rail system within the buffer zone after rerouting the traffic flow. The barrier is removed prior to the final routing step. By installing a barrier within the buffer zone, a defective container handling vehicle will not be able to pass through the buffer zone.

[0028] According to an embodiment, the database is updated using the addresses of the storage columns according to the new physical design. Each storage column typically has a unique address in a Cartesian coordinate system. When the storage and retrieval system is extended in the x- and / or y-directions, the new storage columns can be addressed using coordinates with incremented coordinate values that persist from the coordinates of the existing adjacent storage columns. If the storage and retrieval system is extended in the negative x-direction with respect to an existing storage column addressed as, for example, (1,1), the coordinates that address all the storage columns within it can be offset in the x-direction. A re-assignment of the similar numbers of the addresses of each storage column can be implemented when storage column 105 is removed.

[0029] According to an embodiment, the new storage columns of the reconstructed storage and retrieval system are filled with storage containers, typically increasing the storage capacity of the storage and retrieval system. Storage containers already stored within the existing columns of the zone that are not affected by the storage and retrieval system can be transferred and / or new storage containers can be stored within the new storage columns as soon as they are input into the storage and retrieval system.

[0030] According to the method described above, the present invention is further defined by an automated storage and retrieval system having a control system for controlling the operation of the system during the reconstruction of its physical design. The storage and retrieval system comprises a skeletal structure forming a three-dimensional storage grid structure for storing storage containers, the grid structure forming vertical storage columns each having the same horizontal area defined by the size of the access opening of the vertical storage column, and a rail system being arranged on the skeletal structure defining around each access opening on top of each storage column. The rail system provides an available path for a container handling vehicle for storing storage containers into and out of the storage columns and for loading, unloading and transferring them therefrom. The control system comprises a master controller connected to a route planner and a vehicle controller of the container handling vehicle for controlling the traffic flow of the vehicle according to the route planner. A database is connected to the master controller and / or the route planner. The database comprises layout information of the rail system and location information of the vehicles and storage containers, and the layout information of the rail system is updated in the database at any time during the design step, the temporary route designation step and the final route designation step described above. The route planner is configured to determine an optimal route on the rail system for each vehicle based on the available routes according to the layout information of the rail system stored on the database at that time and the location information of each vehicle and storage container. The available routes from which the route planner selects during the design step, the temporary route designation step and the final route designation step are different in each case.

[0031] The present invention is further defined by a computer program that, when executed by a processor in a control system of an automatic storage and retrieval system, implements the method described above for controlling the automatic storage and retrieval system during the reconstruction of the physical design of the system. The control system may comprise a path designator connected to a database comprising layout information of a rail system and location information of vehicles and storage containers, the path designator determining, as described above, an optimal path on the rail system for each vehicle of the automatic storage and retrieval system based on the layout information and available paths according to the location information of each vehicle and storage container. The present invention provides, for example, the following items. (Item 1) A method (400) for controlling an automatic storage and retrieval system (1) during reconstruction of its physical design, wherein the storage and retrieval system (1) comprises a skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106), the grid structure (104) forms vertical storage columns (105), and each of the vertical storage columns (105) has the same horizontal area defined by the size of the access opening (112) of the vertical storage column (105), a rail system (108) is disposed on the skeletal structure (100) and defines around each access opening (112) on each storage column (105), the rail system (108) provides a path available for a container handling vehicle (201), and the container handling vehicle (201) handles the storage containers (106) and transfers them to and from the storage columns (105), each vehicle (201) comprises a vehicle controller (230) communicating with a master controller (220), the master controller (220) assigns work to each vehicle (201) for handling and transferring the storage containers (106) and controls the traffic flow of the vehicles (201) according to a route planner (200), a database (210) comprising layout information of the rail system (108) and location information of the vehicles (201) and storage containers (106) is connected to the master controller (220) and / or the route planner (200), the route planner (200) determines an optimal route on the rail system (108) for each vehicle (201) based on the available routes according to the layout information of the rail system (108) and the location information of each vehicle (201) and storage container (106), The method - After a design step (410) in which a new physical design of the framework and the corresponding rail system (108) is designed, a step of designing a part of the rail system (108) to be a buffer zone, wherein the rail system (108) is affected by reconstruction (430), and the part of the rail system is to be removed from the automated storage and retrieval system, the step including updating the database (420) with layout information involving the new physical design and the rail system (108) affected by the reconstruction, - A transfer step (440), wherein a storage container (106) having a storage position at a storage location within a lower column (105) of the part of the rail system (108) within the buffer zone and the part of the rail system to be removed is transferred, - A temporary routing step (450), wherein the database (210) updates the layout information of the rail system (108), excludes the part of the rail system within the buffer zone and the part of the rail system to be removed from the available routes, the routing planner (200) re-routes the traffic flow (450) of the container handling vehicle (201) according to the available routes not affected by the reconstruction, and the master controller (220) is instructed by the routing planner to control the vehicle (201) according to the available routes, - After a reconstruction step (460) in which the automated storage and retrieval system (1) is reconstructed according to the new physical design by adding and / or removing a part of the framework and the rail system (108), a final routing step (470) including The layout information of the rail system (108) within the database (210) is updated to include, within the available path, the part of the rail system within the buffer zone and the new part of the constructed rail system (108), and the path designator (200) uses the updated layout information to designate the traffic flow of the vehicle (201) on the rail system (108) after reconstruction of the physical design of the automated storage and retrieval system (1). (Item 2) The method according to item 1, by defining the buffer zone as the storage column (105) that will be removed during reconstruction or the corresponding part of the storage column (105) and the rail system (108) adjacent to the storage column (105) that will be added. (Item 3) The method according to item 1 or 2, wherein the storage container (106) is transferred by moving the storage container (106) to a storage column (105) not affected by the reconstruction and / or to a location outside the storage and retrieval system (1). (Item 4) The method according to item 3, by updating the location information of the database (210) at the new storage location of the transferred storage container (106). (Item 5) The method according to any one of items 1-4, by physically blocking access to the buffer zone by installing a barrier on the part of the rail system (108) within the buffer zone after re-routing the traffic flow (450). (Item 6) The method according to item 5, by removing the barrier prior to the final path designation step (470). (Item 7) The method according to any one of items 1-6, by updating the layout information in the database (210) with the address of the storage column (105) according to the new physical design. (Item 8) The method according to any one of items 1-7, by filling the new storage column (105) of the reconstructed storage and retrieval system (1) with storage containers (106). (Item 9) An automatic storage and retrieval system (1) having a control system (500), wherein the control system (500) controls the operation of the system (1) during the reconstruction of its physical design according to the method described in item 1, and the storage and retrieval system (1) comprises a skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106). The grid structure (104) forms vertical storage columns (105), and each of the vertical storage columns (105) has the same horizontal area defined by the size of the access opening (112) of the vertical storage column (105). A rail system (108) is disposed on the skeletal structure (100), defining around each access opening (112) on each storage column (105), and the rail system (108) provides a path available for a container handling vehicle (201), and the container handling vehicle (201) handles the storage container (106), transfers the storage container (106) to and from the storage column (105). The control system (500) comprises a master controller (220) connected to a route designator (200) and a vehicle controller (230) of the container handling vehicle (201), and the master controller (220) controls the traffic flow of the vehicle (201) according to the route designator (200). A database (210) comprising layout information of the rail system (108) and location information of the vehicle (201) and the storage container (106) is connected to the master controller (220) and / or the route designator (200). The layout information of the rail system is updated from time to time in the database (210) during the design step (410), the temporary route designation step (450), and the final route designation step (470) in the method described in item 1. The route designator (200) is configured to determine an optimal route on the rail system (108) for each vehicle (201) based on the layout information of the rail system (108) stored temporarily on the database (210) and the available routes according to the location information of each vehicle (201) and the storage container (106). The system in which the available routes for selection by the route design planner during the design step (410), the temporary route designation step (460), and the final route designation step (480) are different in each case. (Item 10) A computer program which, when executed by a processor in a control system (500) of an automated storage and retrieval system (1), implements the method according to item 1 for controlling the automated storage and retrieval system (1) during reconstruction of the physical design of the system.

Brief Description of the Drawings

[0032] The following drawings are attached to facilitate the understanding of the present invention. The drawings show embodiments of the present invention, which will be described here only by way of example.

[0033]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

DETAILED DESCRIPTION OF THE INVENTION

[0034] (Reference Numerals) 100 - Skeletal Structure 102 - Upright Member of the Skeletal Structure 103 - Horizontal Member of the Skeletal Structure 104 - Storage Grid Structure 105 - Storage Column 106 - Storage Container 106’ - Specific Position of the Storage Container 107 - Stack 108 - Rail System 110 - Parallel Rails in the First Direction (X) 110a - First Rail in the First Direction (X) 110b - Second Rail in the First Direction (X) 111 - Parallel Rails in the Second Direction (Y) 111a - First Rail in the Second Direction (Y) 111b - Second Rail in the Second Direction (Y) 112 - Access Opening 119 - First Port Column 120 - Second Port Column 200 - Route Designator Planner 201 - Container Handling Vehicle 210 - Database (DB) 220 - Master Controller 230 - Vehicle Controller X - First Direction Y - Second Direction Z - Third Direction 500 - Control System

[0035] In the following description, the present invention will be discussed in more detail with reference to the accompanying drawings. However, it should be understood that the drawings are not intended to limit the present invention to the subject matter depicted therein.

[0036] The skeletal structure 100 of the automatic storage and retrieval system 1 is constructed according to the prior art skeletal structure 100 described above in relation to FIG. 1, i.e., according to several upright members 102 and several horizontal members 103 supported by the upright members 102. Further, the skeletal structure 100 includes a first upper rail system 108 with rails 110, 111 in the X and Y directions. The skeletal structure 100 provides storage compartments in the form of storage columns 105, which are provided between the members 102, 103, and the storage containers 106 can be stacked in stacks 107 within the storage columns 105.

[0037] It should be understood that the skeletal structure 100 can be of any size and can be significantly wider and / or longer and / or deeper than that disclosed in FIG. 1. For example, the skeletal structure 100 can have a horizontal extent larger than 700×700 columns and a storage depth larger than 12 containers.

[0038] As can be understood from the description, the reconstruction of the design of the storage system 1 will affect the rail system 108 such that some of the paths currently used by the container handling vehicle 201 will not be accessible during the reconstruction process. So far, the storage and retrieval system has had to be shut down during reconstruction.

[0039] The present invention provides a method, a system, and a computer program that enable the reconstruction of a storage and retrieval system while it is operating. This means that it is not necessary to shut down the storage and retrieval system while it is being reconstructed.

[0040] Figure 2 shows the components included in a control system 500 for controlling an automatic storage and retrieval system. The master controller 220 is connected to a path designation planner 200 and a vehicle controller 230 in each container handling vehicle 201. A database is connected to the path designation planner 200 and / or the master controller 220. The database 210 includes not only the layout information of the grid structure 104 but also the location information of the vehicles 201 and the storage containers 106.

[0041] The layout of the storage system 1 is typically described according to the Cartesian x, y - coordinates that define each storage column 105, as shown in Figure 3. The coordinates of each storage column 105 will also reflect the layout of the rail system 108 since each storage column 105 has a part of the rail system 108 on its top.

[0042] The path designation planner 200 includes a processor, and the processor launches a computer program for determining the optimal path on the rail system 108 for each job assigned to the vehicle 201. A job can be, for example, retrieving a specific storage container from a specific storage column 201 and delivering it to a specific port column for further handling. The optimal path will be based on the layout information of the rail system 108 and the currently available paths. The path designation planner 200 will instruct the master controller 220 to control each vehicle 201 according to the available and optimal path for the assigned job. The optimal path will typically be the shortest and / or fastest path for a job that does not conflict with the paths of other vehicles. The master controller will then transmit a control command to each container handling vehicle 201, and the control command will include information about the job to be performed and the path to take for that job.

[0043] The method implemented for controlling the automatic storage and retrieval system 1 during the reconstruction of its physical design will be described here with reference to Figures 3 - 7.

[0044] Figure 3 shows a top view of an exemplary existing design of the storage and retrieval system 1. For the sake of convenience, the figure illustrates an example of a small storage system with a total of 60 storage columns. Each storage column is uniquely identified by its address / coordinates. For example, the upper left storage column in the figure is identified by its x, y - coordinates (1,1), and the lower right is identified by (10,7).

[0045] The rail system 108 is disposed on the framework structure 100 that defines around each access opening 112 above each storage column 105. The resulting grid pattern of the rail system 108 provides different paths for each container handling vehicle 201.

[0046] When the storage and retrieval system 1 is to be rebuilt according to a new design, the first step of this method is to design a new framework and the corresponding rail system 108.

[0047] Figure 4 shows an example of a modified and exemplary rebuilt design of the storage system 1 shown in Figure 3. In this new design, the storage column 105 addressed as (6,7)-(10,7) is removed, and a new storage column 105 addressed as (11,1)-(11,6) is added. When storage columns 105 with the corresponding rail system 108 are added or removed from the existing storage and retrieval system 1, a part of the rail system 108 on the existing adjacent storage columns 108 can be affected by the reconstruction and cannot be used for the container handling vehicle 201.

[0048] When the storage and retrieval system 1 expands in the x- and / or y-directions, new storage columns can be addressed using coordinates with incremented coordinate values that follow from the coordinates of the existing adjacent storage column 105. For example, when the expansion is in the positive x- and / or y-directions represented by east (E) and south (S) directions in FIG. 3, the integer values are incremented. This is reflected by the newly marked columns in FIG. 4.

[0049] On the other hand, when the storage and retrieval system 1 expands in the negative x- and / or y-directions represented by west (W) and north (N) in FIG. 3, the coordinates addressing all the storage columns can be displaced such that the storage column 105 located in the upper left (N / W) in FIG. 3 starts with (1,1) as its coordinates. A similar re-assignment of the addresses of each storage column can be implemented when a storage column 105 is removed.

[0050] FIG. 5 illustrates that, in addition to the storage columns where the storage column 105 is removed or reconstructed, the storage system can be affected when it is reconstructed according to the new design shown in FIG. 4. This "buffer zone", shown hatched in FIG. 5, comprises a part of the rail system 108 above the storage column 105 that can be affected by removing or adding adjacent storage columns 105. A part of the rail system 108 within the buffer zone and a part of the rail system 108 on the storage column to be removed cannot be used during reconstruction.

[0051] To ensure that the container handling vehicle 201 avoids using the parts of the rail system 108 within the buffer zone and the area being removed, the storage columns 105 within the affected parts of the rail system 108 are temporarily excluded from the available paths during the reconstruction of the storage system 1. In the illustrated example, the storage columns 105 excluded from the buffer zone are (10,1)-(10,6) and (6,6)-(6,9). These are in addition to the storage columns being removed or reconstructed, i.e., (6,7)-(10,7) and (11,1)-(11,6) in the illustrated example.

[0052] Figure 6 illustrates zones not affected by the storage columns 105. These storage columns 105 provide available paths to the path planner during the reconstruction phase. The storage and retrieval system will typically operate within this non - affected zone during the reconstruction phase. In the example used here, the available path will be on the rail system 108 over 45 storage columns 105 addressed as (1,1)-(9,5).

[0053] Figure 7 is a flowchart illustrating different steps implemented according to a method 400 for controlling the automated storage and retrieval system 1 during the reconstruction of its physical design.

[0054] The steps of the method illustrate different phases, namely, the planning and design phase, the transfer phase, the re - routing phase, the reconstruction phase, and the final routing phase.

[0055] In the planning and design phase, a new design is established by the new or modified grid layout of storage system 1 and the design step 410 of rail system 108. This is typically carried out on a computer that launches a CAD program, and the new design can be visualized and verified prior to implementation. The computer program can be operated by a person designing the new layout or program, or the program can automatically propose a new grid design based on the information of the modified as-built drawing of the facility when storage system 1 is installed. The proposed grid design can then be approved or rejected by the operator.

[0056] As described, the center of storage system 1 is database 210, which contains updated data with the layout information of the skeleton of storage grid structure 104, rail system 108, and the location information of container handling vehicle 201 and storage container / bin 106.

[0057] Once the new grid design and corresponding rail system 108 are determined, database 210 is updated 420 with this information. The portion of rail system 108 affected by the reconstruction, i.e., the portion of rail system 108 on the storage columns within the buffer zone adjacent to the portion of rail system 108 on the storage columns where additional or removed storage columns are located, will then be defined 430 by comparing the existing design with the new reconstructed design.

[0058] The database 210 continues to track the different storage containers 106 within the storage columns 105 where they are currently stored. The next step is to identify and transfer 440 the storage containers 106 stored within the storage columns 105 below the rail system 108 that are to be excluded from the available paths (e.g., within the buffer zone and below the portion of the rail system being removed). The identified storage containers 106 are then transferred to storage columns 105 below the rail system 108 that will, for example, not be affected by the reconstruction. Storage containers 106 stored within storage columns 105 that will be removed in the new design will also be transferred prior to the reconstruction process.

[0059] Once the relevant storage containers 106 are transferred, the portions of the rail system that will be affected by the reconstruction (e.g., portions within the buffer zone and portions above the removed storage columns) can then be excluded from the selection of available paths, the database 210 is updated 420 with this information, and the traffic flow of the container handling vehicles 201 will be temporarily re-routed 450 according to the identified available paths during the reconstruction process 460.

[0060] The re-routing is performed by the route planner 200 according to the updated information on the available paths during the reconstruction process. The route planner 200 instructs the master controller 230 within each vehicle 201 assigned the task of transporting the storage containers 106 to control and route the vehicle 201 according to the temporarily available paths.

[0061] Once the temporary re-routing step is implemented, the automated storage and retrieval system 1 can be reconstructed according to the new physical design by adding and / or removing parts of the framework and the rail system 108.

[0062] Once the reconstruction is complete, the portions of the rail system 108 within the buffer zone previously excluded from the selection of available routes, and the new portions of the rail system 108 being constructed, are here included as available routes, and the route designator 200 implements a final route designation step 470 in which the traffic flow of the vehicle 201 is controlled according to the available routes on the rail system 108 after reconstructing the physical design of the automated storage and retrieval system 1.

[0063] The new storage columns 105 of the reconstructed storage and retrieval system 1 are filled, according to one embodiment, with new storage containers 106. This is typically the case when the storage and retrieval system 1 is expanded with additional storage columns 105.

[0064] In one embodiment, the physical blocking of the excluded portions of the rail system 108 is carried out after step 450 of rerouting the traffic flow. The physical blocking may comprise objects such as barriers, which are adapted to fit within or on the rail system 108 when installed on the portions of the rail system 108 to be excluded and are stationary. The physical barriers would improve safety during the reconstruction process. The physical barriers are removed prior to the final route designation step 470.

[0065] The route designation steps of the method described above are carried out by a computer program executed by a processor in a route designator 200 connected to a database 210 of vehicles 230 and a controller 220. All of these devices have been described above with reference to FIG. 2 and they form part of the control system 500 of the automated storage and retrieval system 1.

[0066] The foregoing description is not intended to be construed in a limiting sense. On the contrary, various modifications and variations of the illustrative embodiments, which are obvious to those skilled in the art, and other embodiments of the system that are attendant to the disclosed subject matter are considered to be within the scope of the present invention.

Claims

Claim 1 A method (400) for controlling an automated storage and retrieval system (1) during reconstruction of the physical design of the automated storage and retrieval system (1), wherein the automated storage and retrieval system (1) comprises a skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing a plurality of storage containers (106), the grid structure (104) forms a plurality of vertical storage columns (105), and each of the plurality of vertical storage columns (105) has the same horizontal area defined by the size of the access openings (112) of the plurality of vertical storage columns (105), a rail system (108) is disposed on the skeletal structure (100), the rail system (108) defines around each access opening (112) above each vertical storage column (105), the rail system (108) provides a plurality of available paths for a plurality of container handling vehicles (201), the plurality of container handling vehicles (201) handle the plurality of storage containers (106), transfer the plurality of storage containers (106) to the plurality of vertical storage columns (105), and transfer the plurality of storage containers (106) from the plurality of vertical storage columns (105), each vehicle (201) comprises a vehicle controller (230) communicating with a master controller (220), the master controller (220) assigns work to each vehicle (201) for handling and transferring the plurality of storage containers (106), and controls the traffic flow of the plurality of vehicles (201) according to a route planner (200), a database (210) comprising layout information of the rail system (108) and location information of the plurality of vehicles (201) and the plurality of storage containers (106) is connected to the master controller (220) and / or the route planner (200), the route planner (200) determines an optimal path on the rail system (108) for each vehicle (201) based on the plurality of available paths according to the layout information of the rail system (108) and the location information of each vehicle (201) and each storage container (106), the method comprises - After a design step (410) in which a new physical design of the skeletal structure (100) and the rail system (108) is designed, a step of designating the first part of the rail system (108) such that the first part of the rail system (108) is within a buffer zone, the rail system (108) being affected by reconstruction (430), a second part of the rail system (108) being to be transferred in the automated storage and retrieval system (1), the step including updating (420) the database (210) with layout information involving the new physical design and the rail system (108) affected by the reconstruction, a step; - A transfer step (440) in which a plurality of storage containers (106) having a plurality of storage positions at storage locations within a vertical storage column (105) below the first part of the rail system (108) within the buffer zone and the second part of the rail system (108) to be removed are transferred, a transfer step (440); - A temporary route designation step (450) in which the database (210) updates the layout information of the rail system (108) to exclude the first part of the rail system (108) within the buffer zone and the second part of the rail system (108) to be removed from the plurality of available routes, the route designation planner (200) re-routes the traffic flow (450) of the plurality of container handling vehicles (201) according to the plurality of available routes not affected by the reconstruction, and the master controller (220) is commanded by the route designation planner to control the plurality of vehicles (201) according to the plurality of available routes, a temporary route designation step (450); - After a reconstruction step (460) in which the automatic storage and retrieval system (1) is reconstructed according to the new physical design by adding and / or removing parts of the skeletal structure (100) and the rail system (108), a final route designation step (470), wherein the layout information of the rail system (108) in the database (210) is updated to include the first part of the rail system (108) within the buffer zone and the new part of the constructed rail system (108) within the plurality of available routes, and the route designation planner (200) uses the updated layout information to designate the traffic flow of the plurality of vehicles (201) on the rail system (108) after reconstructing the physical design of the automatic storage and retrieval system (1), the final route designation step (470) A method including. **Claim 2** The method according to claim 1, wherein the buffer zone is defined by the plurality of vertical storage columns (105) adjacent to the plurality of vertical storage columns (105) to be removed or added during reconstruction and the corresponding parts of the rail system (108). **Claim 3** In the transfer step (440), the plurality of storage containers (106) are transferred by moving the plurality of storage containers (106) to a plurality of vertical storage columns (105) not affected by the reconstruction and / or by moving the plurality of storage containers (106) to a location outside the automatic storage and retrieval system (1). The method according to claim 1 or 2. **Claim 4** The method according to claim 3, further including updating the location information in the database (210) at the plurality of new storage locations of the plurality of storage containers (106) that have been transferred after the transfer step. **Claim 5** The method according to any one of claims 1 to 4, further including physically blocking access to the buffer zone by installing a barrier on the first part of the rail system (108) within the buffer zone after rerouting the traffic flow (450). **Claim 6** The method according to claim 5, further comprising removing the barrier prior to the final path designation step (470).

7. The method according to any one of claims 1 to 6, further comprising updating the layout information in the database (210) with addresses of a plurality of vertical storage columns (105) according to the new physical design.

8. The method according to any one of claims 1 to 7, further comprising filling a plurality of new vertical storage columns (105) of the automated storage and retrieval system (1) with a plurality of storage containers (106) after the reconstruction step.

9. An automated storage and retrieval system (1) having a control system (500), wherein the control system (500) controls the operation of the automated storage and retrieval system (1) during reconstruction of the physical design of the automated storage and retrieval system (1) according to the method according to claim 1, and the automated storage and retrieval system (1) comprises a skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing a plurality of storage containers (106), the grid structure (104) forms a plurality of vertical storage columns (105), and each of the plurality of vertical storage columns (105) has the same horizontal area defined by the size of the access openings (112) of the plurality of vertical storage columns (105), a rail system (108) is disposed on the skeletal structure (100), the rail system (108) defines around each access opening (112) on each vertical storage column (105), the rail system (108) provides a plurality of available paths for a plurality of container handling vehicles (201), and the plurality of container handling vehicles (201) handle the plurality of storage containers (106), transfer the plurality of storage containers (106) to the plurality of vertical storage columns (105), and transfer the plurality of storage containers (106) from the plurality of vertical storage columns (105). The control system (500) includes a master controller (220), and the master controller (220) is connected to a route design planner (200) and a plurality of vehicle controllers (230) of a plurality of container handling vehicles (201). The master controller (220) controls the traffic flow of the plurality of vehicles (201) according to the route design planner (200). A database (210) having the layout information of the rail system (108) and the location information of the plurality of vehicles (201) and the plurality of storage containers (106) is connected to the master controller (220) and / or the route design planner (200). The layout information of the rail system (108) is updated in the database (210) during the design step (410), the temporary route designation step (450), and the final route designation step (470) in the method according to claim 1. The route design planner (200) is configured to determine an optimal route on the rail system (108) for each vehicle (201) based on the layout information of the rail system (108) stored on the database (210) and the location information of each vehicle (201) and each storage container (106) according to the plurality of available routes. The plurality of available routes selected by the route design planner during the design step (410), the temporary route designation step (460), and the final route designation step (480) are different from each other, automated storage and retrieval system (1).

10. A computer program, which when executed by a processor in a control system (500) of an automated storage and retrieval system (1), executes the method according to claim 1 to control the automated storage and retrieval system (1) during the reconstruction of the physical design of the automated storage and retrieval system (1).

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