Automatic storage and retrieval system

Abstract

To provide an ASR system that improves storage density at low cost and with a small footprint without significantly affecting system throughput. In a material handling system for storing or retrieving items to or from a plurality of destination areas, the items are loaded onto one of a plurality of transport vehicles that follow a route to and from the destination areas arranged along a path, the destination areas configured to have a depth for accommodating a plurality of storage containers horizontally behind one another, the plurality of storage containers may be releasably interconnected, and retrieving one of the interconnected storage containers moves one or more of the connected storage containers.

Description

Reference to Related Applications

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 463,352, filed Feb. 24, 2017, and U.S. Patent Application No. 15 / 905,810, filed Feb. 26, 2018. Accordingly, the entire disclosures of each of the foregoing applications are hereby incorporated by reference herein.

Technical Field

[0002] The present invention relates to a material handling system for transporting one or more objects from a first position to a second position, and more particularly to an automated storage and retrieval system in which a plurality of storage containers are stored in a plurality of storage locations, where some of the storage containers are located behind other storage containers.

Background Art

[0003] Many large organizations have vast storage areas for storing and retrieving countless and diverse items, for example, to fulfill customer orders. Manually sorting and retrieving items for hundreds or thousands of storage areas requires a huge amount of labor. In many fields, automated picking has been developed to reduce labor costs, reduce the time required to fulfill customer orders, and improve customer service. Often, there are trade - offs among variables when setting up a system, such as storage density, accessibility, footprint, cost, etc. For example, by improving the storage density of an automated storage and retrieval (ASR) system, both the cost and space requirements (footprint) of such an automated storage and retrieval system can be reduced. However, if the storage density of an automated storage and retrieval system is too high, the ease and speed of storing and retrieving individual items may decrease, and the automated storage and retrieval system may not be suitable for many applications.

[0004] As an example, the automatic storage and retrieval system includes a plurality of independently operating vehicles. Such an automatic storage and retrieval system is configured as a passageway with storage locations on both sides, and the vehicle moves along a path within the passageway. The capacity of the automatic storage and retrieval system can be increased by making the passageway higher or longer. Alternatively, additional passageways may be added. However, in many situations, such an automatic storage and retrieval system may not be space - available, or the cost may exceed the advantage of increased capacity. Therefore, for some applications, there is a need for an ASR system that can improve storage density at low cost and with a small footprint without significantly affecting the system throughput. SUMMARY OF THE INVENTION

[0005] In light of the above, the automatic storage and retrieval system provides a method and apparatus for storing and retrieving items. The present automatic storage and retrieval system includes a plurality of storage locations or destination areas, and a plurality of carrier vehicles for delivering items to the destination areas or retrieving items from the destination areas. The carrier vehicle follows a path to the destination area.

[0006] The present invention may also provide an improved material handling automatic storage and retrieval system. In this automatic storage and retrieval system, an independently operable vehicle is operable to deliver a storage container to a storage location and retrieve it from the storage location, and the storage location has a depth sufficient to horizontally accommodate a plurality of storage containers in a front - to - back arrangement. This automatic storage and retrieval system may include a track for guiding the vehicle along a track to the storage location. In addition, the storage locations may be arranged such that a plurality of storage locations are spaced apart in a direction perpendicular to each other. For example, the storage location may be configured as an array of a plurality of row - or column - shaped storage locations. Further, the storage container may be releasably connectable to an adjacent storage container, and by doing so, when the first storage container in the first storage location is moved, the second storage container moves within the first storage location.

[0007] The present invention also provides a material handling system for storing or retrieving a plurality of items, including a plurality of independently operable vehicles for delivering and retrieving the items to a destination. Optionally, the automated storage and retrieval system includes a track for guiding the vehicle. The automated storage and retrieval system includes a plurality of storage locations, and the plurality of storage locations are arranged spaced apart in a direction perpendicular to each other. The storage locations may be arranged along the track. The automated storage and retrieval system also includes a plurality of storage containers. One or more storage locations are configured to accommodate a plurality of storage containers. The storage container includes a connector for interconnecting a plurality of storage containers stored adjacent to each other within the storage location. When the connector connects a plurality of storage containers, moving one of the storage containers in the storage location exposes the interconnected storage containers in the same storage location. The vehicle may include a transport mechanism configured to transport the storage container between the vehicle and the storage location. And this transport mechanism may be operable to move the interconnected first container and second storage container when the first container or the second storage container moves relative to the vehicle.

[0008] According to another aspect, the material handling system may include a track system having a plurality of generally horizontal track sections arranged spaced apart from each other. Also, the track system may include a plurality of generally vertical track sections arranged spaced apart from each other. The vertical and horizontal track sections may be interconnected to form a circular track.

[0009] Furthermore, according to another aspect, the present invention provides a storage container for a material handling system having a first connector and a second connector. These connectors can provide a connection that prevents horizontal movement of the first storage container relative to the second storage container. The connection between the first connector and the second connector may be sufficient to support the weight of the second storage container during horizontal movement, such that when the first storage container is moved horizontally while the first connector and the second connector are connected, the second storage container moves horizontally. Furthermore, the connection between the first connector and the second connector may allow vertical movement of the first storage container relative to the second storage container.

[0010] According to another aspect, an automated storage and retrieval system may provide a storage container having a first connector and a second connector for releasably connecting a first storage container and a second storage container, wherein the first connector and the second connector are configured such that when the first connector moves vertically relative to the second connector, the first connector is disengaged from the second connector.

[0011] Furthermore, the present invention provides a storage container having a first connector and a second connector for interconnecting storage containers with each other, wherein the first connector includes a tongue and the second connector includes a groove configured to receive the tongue.

[0012] According to another aspect, the present invention provides a storage location where a first storage container and a second storage container are disposed, the storage location being configured to accommodate the first storage container and the second storage container along a horizontal direction, and the first storage container being disposed in front of the second storage container. Optionally, the storage location may be configured such that when a transport vehicle follows the first storage container, the first storage container separates the second storage container from the transport vehicle.

[0013] Furthermore, the present invention provides a material handling system having a plurality of storage locations, each storage location being configured to store a plurality of storage containers. Optionally, each storage location has a depth, the first storage container and the second storage container of the storage containers each have a length, and the depth of the storage location has a length at least as long as the total length of the first storage container and the second storage container.

[0014] According to another aspect, the present invention provides a transport vehicle for a material handling system, each vehicle having a substantially planar platform for receiving a storage container.

[0015] Furthermore, according to another aspect, the present invention provides a material handling system comprising a first storage rack of a storage location located away from a second storage rack of the storage location, a passage being formed between the first storage rack and the second storage rack.

[0016] Optionally, the material handling system may include a collection station disposed at an end of the passage. The vehicle delivers the storage container to the collection station, and an operator can obtain items from the storage container at the collection station.

[0017] According to another aspect, the material handling system may include a vehicle movable within the passage. The vehicle may include drive wheels that engage a track, and the storage rack of the storage location may be positioned relative to the track such that the storage container projects horizontally into the passage beyond the track.

[0018] According to a further aspect, the present invention provides a storage container for a material handling system, the storage container including one or more engagement elements configured to engage a transport mechanism of a vehicle that delivers the storage container.

[0019] According to a further aspect, the present invention provides a storage container for use in a material handling system for storing or obtaining a plurality of items. The storage container includes a plurality of walls, a first connector, and a second connector. The first connector and the second connector are configured to be able to form a releasable connection between two storage containers so that they can be connected. The storage container may include engagement elements configured to cooperate with a transport mechanism that also serves as a loading / unloading mechanism of the material handling system to horizontally move the storage container. Furthermore, the material handling system may include a storage location, and the length of the storage container may be less than or equal to half of the depth of the storage location. Thereby, when two storage containers are connected together, the two storage containers fit within the storage location. Also, the first connector and the second connector may be connectable to form a releasable connection.

[0020] Furthermore, the present invention may provide a combination of a first storage container and a second storage container for use in a material handling system. The two storage containers may be similarly configured, and the first connector of the first storage container is connectable to the second connector of the second storage container to connect the two storage containers, and by horizontally moving the first storage container by the transport mechanism of the transport vehicle, the second storage container is moved. Optionally, the connection between the first connector of the first storage container and the second connector of the second storage container prevents the horizontal movement of the first storage container relative to the second storage container.

[0021] The present invention also provides a method for storing and retrieving storage containers from a plurality of storage locations. This method includes the step of driving a first vehicle having a first storage container along a transfer path between a plurality of storage locations. The first storage container is unloaded from the first vehicle to the first storage location. The first storage container is releasably connected to a second storage container within the first storage location. And after the step of loading and unloading, move the first vehicle from the first storage location.

[0022] According to another aspect, a method for storing and retrieving a storage container includes the step of separating a first storage container within a storage location from a second storage container within the storage location. Optionally, the step of releasably connecting includes the step of moving the first storage container in a direction perpendicular to the second storage container.

[0023] According to a further aspect, a method for storing and retrieving a storage container using a vehicle includes the step of separating a connected first storage container and a second storage container by moving the first storage container in a direction perpendicular to the second storage container.

[0024] Furthermore, according to another aspect, a method for storing and retrieving a storage container using a vehicle includes, after the step of releasably connecting a first storage container and a second storage container, the step of loading the first storage container onto the vehicle, whereby, during the loading step, the first storage container pulls the second storage container towards the vehicle.

[0025] According to a further aspect, a method for storing and retrieving a storage container using a vehicle includes the step of loading and unloading the first storage container at a storage location. The loading and unloading step includes the step of pushing the first storage container towards the second storage container to move the second storage container deeper into the storage location. The loading and unloading step may include the step of operating a loading and unloading mechanism on the first vehicle to move the first storage container out of the first vehicle.

Brief Description of the Drawings

[0026] The foregoing summary and the following detailed description of embodiments of the invention are best understood when read in conjunction with the accompanying drawings.

[0027] Figure 1 is a perspective view of the storage and retrieval device.

[0028] Figure 2 is a partial side view of the track of the storage and retrieval device shown in Figure 1.

[0029] Figure 3 is an enlarged perspective view of the vehicle of the storage and retrieval device shown in Figure 1.

[0030] Figure 4 is an enlarged perspective view of the gate of the track shown in Figure 2.

[0031] Figure 5 is an enlarged perspective view of the gate of the track shown in Figure 2.

[0032] Figure 6 is an enlarged perspective view of the gate of the track shown in Figure 2.

[0033] Figure 7 is a partially enlarged view of the wheels of the vehicle shown in Figure 3 and a part of the track shown in Figure 2.

[0034] Figure 8 is a schematic side view of a plurality of storage locations of the device shown in Figure 1.

[0035] Figure 9 is a schematic side view of the storage container inside the storage location of the device shown in Figure 1.

[0036] Figure 10A is a schematic diagram showing the steps of the process of moving the storage container of Figure 9 from one location to another.

[0037] Figure 10B is a schematic diagram showing the steps of the process of moving the storage container of Figure 9 from one location to another.

[0038] Figure 10C is a schematic diagram showing the steps of the process of moving the storage container of Figure 9 from one location to another.

[0039] Figure 10D is a schematic diagram showing the steps of the process of moving the storage container of Figure 9 from one location to another.

[0040] Figure 10E is a schematic diagram showing the steps of the process of moving the storage container of Figure 9 from one location to another.

[0041] Figure 10F is a schematic diagram showing the steps of a process of moving the storage container of FIG. 9 from one location to another location.

[0042] Figure 10G is a schematic diagram showing the steps of a process of moving the storage container of FIG. 9 from one location to another location.

[0043] Figure 10H is a schematic diagram showing the steps of a process of moving the storage container of FIG. 9 from one location to another location.

[0044] Figure 11 is a partial perspective view of the storage rack of the material handling apparatus shown in FIG. 1.

[0045] Figure 12 is a partial perspective view including the vehicle of the storage rack of the material handling apparatus shown in FIG. 1.

[0046] Figure 13 is a partial side view in which a plurality of releasable storage containers of the material handling apparatus shown in FIG. 1 are connected.

[0047] Figure 14 is a partial side view in which a plurality of releasable storage containers of the material handling apparatus shown in FIG. 1 are separated.

DETAILED DESCRIPTION OF THE INVENTION

[0048] Referring now to FIG. 1, a material handling apparatus adapted to store and / or retrieve items is generally designated by the reference numeral 10. The material handling apparatus 10 includes a plurality of vehicles 200 that transfer items along a transfer path between a first location and a second location. The first location is a storage location selectable from among a plurality of storage locations 50 in one or more storage racks, and the second location is an article transport station 300, a collection station, where items are collected, sorted, and / or transported to a storage container 80 such as a storage container. The material handling apparatus 10 moves an item (or a storage container containing the item) along the transport path.

[0049] The material handling device 10 includes a plurality of transfer vehicles or vehicles 200, and these vehicles 200 move along one or more paths within a passage 20 adjacent to one or more storage racks 35 and 40. The storage racks 35 and 40 are configured to store a plurality of storage containers 80. For example, as shown in FIG. 1, the passage 20 may be an elongated passage formed between a pair of storage racks 35 and 40 such that the vehicle 200 moves within the passage 20 along one or more paths. The track 110 may provide one or more paths within the passage 20 for the vehicle 200 to move to storage locations within the storage rack. For example, an embodiment may include a front track 115 adjacent to the front storage rack 35 on one side of the passage 20. The passage 20 may be formed by disposing a rear track 120 adjacent to the rear storage rack 40 at an interval from the front track 115. The vehicle 200 may move within the passage 20 along the track 110. For example, the vehicle 200 may be supported by one or more front wheels that engage with the front track 115 and one or more rear wheels that engage with the rear track 120.

[0050] Each storage rack 35 and 40 provides a plurality of storage locations 50 for storing storage containers 80 that store various items. The vehicle 200 moves to the storage location 50 along the track 110. At the storage location 50, the vehicle 200 can transport items from the vehicle 200 to one of the storage locations 50. Similarly, the vehicle 200 can transport items from one of the storage locations 50 onto the vehicle 200. Furthermore, the vehicle 200 may be configured to transport items from the vehicle 200 to the storage location 50 while simultaneously transporting items from a different storage location 50 onto the vehicle 200. The storage locations 50 may be arranged as an array of locations adjacent to the passage 20. In addition, as further described below, the storage racks 35 and 40 may provide a storage depth that allows the storage containers 80 to be stored in two or more depths in order to improve the storage density of the storage containers 80 within these storage racks. <Storage rack>

[0051] The storage racks 35 and 40 and the storage locations 50 within these storage racks 35 and 40 will be described in more detail here. Referring to FIG. 1, the material handling system may include one or more storage racks 35 and storage racks 40. The storage rack 35 and the storage rack 40 may provide an arrangement of destination areas or storage locations 50 for receiving items. The storage locations 50 may be arranged in columns, but the storage locations 50 may be arranged in any form of various configurations (such as in rows). The material handling system delivers items to and / or retrieves items from the storage area 50. The items may be configured such that individual items are stored in the storage locations 50. However, in a general operating environment, the items are stored in a storage mechanism such as a storage container or a platform.

[0052] Here, with reference to FIGS. 8 to 12, the storage racks 35 and 40 and, in particular, the storage locations 50 will be described in more detail. The storage location 50 may be of any of various configurations. For example, the simplest configuration is a shelf for supporting an item or a storage container 80 that holds the item. Similarly, the storage location 50 may include one or more brackets that support the storage mechanism at the storage location 50 by cooperating with the storage mechanism.

[0053] As shown in FIGS. 8 and 11 to 12, the storage rack 35 may include a plurality of vertical supports 130 such as vertical support beams, which are interconnected with a plurality of horizontal supports such as horizontal beams. In this example, the track 110 may form part of the vertical support beam and the horizontal support beam. For example, the storage rack 35 may be provided with an array of columns. Here, each column is formed by a plurality of supports. Each column may be defined by two front vertical support beams and two rear vertical support beams. As shown in FIG. 11, the vertical support 130 consisting of the front vertical support beam may be provided with a vertical section of the track 110. Each column may include a plurality of storage locations 50. Specifically, each column is divided into a plurality of storage areas or cells 50. Each cell 50 includes support elements that support the storage container 80 so that the storage container 80 can be stored in the cell. The support element may be any of various elements for supporting the storage container 80 at the storage location 50. For example, each storage location 50 may include a shelf or other horizontal support on which the storage container 80 can be placed. For example, as shown in FIGS. 8, 11, and 12, the storage rack 35 may include a plurality of brackets such as L-channels 52 attached to the vertical supports 130. The bracket consisting of this L-channel 52 may extend substantially to the back of each storage location 50. In this way, each storage location 50 extends between a plurality of adjacent vertical supports 130, and is defined as an upwardly extending region from a position adjacent to a pair of horizontal support elements 52 to a position adjacent to a pair of upper horizontal supports or a position adjacent to the upper part of the storage rack.

[0054] Furthermore, as shown in FIG. 11, each storage location 50 may be configured such that the storage container 80 protrudes inwardly toward the passageway and the inner end of the storage container 80 protrudes inwardly beyond the vertical support. In other words, the storage container 80 may be stored in the storage location 50 such that the inner end of the storage container 80 (with respect to the passageway 20) extends beyond into the passageway 20.

[0055] Here, referring to FIG. 9, the storage rack may be configured such that one or more storage locations 50 have a depth sufficient to accommodate a plurality of storage containers 80. For example, one or more storage locations 50 may have a depth of at least about twice the length of the storage container 80 and be able to store two storage containers 80, with one storage container 80 stored behind the other storage container 80. The storage location 50 may be configured to accommodate any number of storage containers 80. For example, the storage racks 35, 40 may be configured such that one or more storage locations 50 can accommodate three storage containers 80, and as a result, the storage containers 80 are arranged in a three-tier depth. In such an embodiment, the storage location 50 has a depth of about three times the length of the storage container 80. Similarly, if the depth of the storage rack is increased to about "n" times the length of the storage container 80, "n" storage containers 80 can be accommodated in the depth of "n". Here, "n" is an integer.

[0056] In the arrangement of FIG. 9, it is shown in relation to an arrangement for storing the storage containers 80 in an "n"-depth arrangement. Here, "n" = 2. The material handling apparatus 10 may include only one storage rack on one side, but in FIG. 9, it has two storage racks, namely, a front storage rack 35 and a rear storage rack 40. Furthermore, the front storage rack 35 and the rear storage rack 40 are configured to accommodate the storage containers 80 in a two-tier depth arrangement. However, it is not necessary to configure the storage racks 35 and 40 to accommodate the same number of storage containers 80. For example, the front storage rack 35 may be configured as a storage rack with a depth of two units, and the rear storage rack 40 may be configured as a storage rack with a depth of one unit.

[0057] In the following description, the storage locations will be described in relation to the arrangement shown in FIGS. 8 to 9. Each storage location 50 includes an inner storage location 55 and an outer storage location 57. Each of the inner storage location 55 and the outer storage location 57 is configured to accommodate a storage container 80. The inner storage location 55 is adjacent to the passage 20. The outer storage location 57 is behind the inner storage location 55, and thus the inner storage location 55 separates the outer storage location 57 from the passage 20 and the vehicle 200. In this example, the inner storage location 55 has a depth approximately the same as the length of the storage container 80. Similarly, the outer storage location 57 has a depth approximately the same as the length of the storage container 80. Since the outer storage location 57 is separated from the passage 20 by the inner storage location 55, it is regarded as a remote storage location. In a system with a depth of more than two units, the remote locations include storage locations separated from the passage 20 by the inner storage location 55 and one or more outer storage locations 57.

[0058] As described above, the material handling system may include a plurality of vehicles 200 that are transported to the storage location 50 and transport items to and from the storage location 50. In particular, the vehicle 200 may include a loading / unloading mechanism 210 for transporting an item to the storage location 50 or withdrawing an item from the storage location 50. In an embodiment where the storage containers 80 are stored in a depth of two or more units, the vehicle 200 is configured to be able to retrieve a storage container 80 stored in one of the remote storage locations 57. For example, each vehicle 200 may include a loading element that extends outwardly to a remote storage location 57 and engages a storage container 80 at the remote storage location 57 to move the storage container 80 to an inner storage location 55 and / or to load the storage container 80 from the remote storage location 57 onto the vehicle 200. Alternatively, another mechanism may be utilized to move the storage container 80 from the remote storage location 57 to the inner storage location 55. For example, the storage rack may include a drive mechanism operable to drive the storage container 80 from the remote storage location 57 towards the passageway 20. The drive mechanism may be powered separately or may interact with one of the drive mechanisms of the vehicle 200. Yet another alternative is to interconnect the storage containers 80 within the remote storage location 57 with adjacent storage containers 80 such that when one of the storage containers 80 is moved, both storage containers 80 move. For example, the storage containers 80 within the remote storage location 57 may be releasably connected to the storage containers 80 within the inner storage location 55. When the storage container 80 within the inner storage location 55 moves towards the passageway 20, the storage container 80 within the remote storage location 57 moves towards the inner storage location 55.

[0059] Here, referring to FIGS. 11 to 14, the storage container 80 is configured to connect with adjacent storage containers. Specifically, the storage container 80 is configured to releasably connect with one or more adjacent storage containers 80. For example, as shown in FIG. 13, a releasable connector 90 connects two adjacent storage containers 80A and 80B. The releasable connector 90 selectively connects the two storage containers 80A and 80B. By doing so, when the storage container 80A is moved horizontally, the storage container 80B also moves. In addition, the releasable connector 90 may allow relative movement in a second or lateral direction while preventing relative movement in one direction. For example, the connection may connect the storage containers 80A and 80B such that when one storage container 80 moves horizontally, the other storage container 80 also moves. At the same time, the releasable connector 90 may be configured to allow one storage container to move vertically relative to the other storage container. In the embodiments shown in FIGS. 11 and 13 - 14, the releasable connector 90 is configured to allow relative vertical movement to connect or disconnect two adjacent storage containers 80A, 80B, as will be further described below.

[0060] In the following discussion, the details of the storage container 80 will be described. The storage container 80 may be a lidless carton or box, etc., and an operator can easily reach into the storage container 80 to obtain an item at the collection location. Although the system is described as using the storage container 80, it should be understood that any of a variety of storage mechanisms, such as pallets or similar platforms, can be used. Accordingly, in the following description, the term "storage container 80" is intended to include items for the purpose of storing and / or supporting items, including but not limited to pallets, platforms, trays, cartons, boxes, containers, or similar structures.

[0061] The storage container 80 may be a rectangular parallelepiped having a substantially flat bottom 83. The bottom 83 is substantially horizontal and forms a platform for obtaining items. The storage container 80 may also include a plurality of substantially vertical walls extending upward from the bottom 83. For example, the storage container 80 may include a plurality of substantially parallel side walls 82. The storage container may include a front wall 84 that protrudes upward from the bottom 83. The front face may extend between a plurality of side walls 82 to connect the side walls 82. Furthermore, the storage container 80 may include a rear wall 86 that protrudes upward from the bottom 83. The rear wall 86 may be substantially parallel to the front wall 84. The rear wall 86 may extend between a plurality of side walls 82 and connect the side walls 82. Therefore, the walls (82, 83, 84, 86) of the storage container 80 define an internal space capable of storing items.

[0062] The storage container 80 may include one or more elements configured to transport the storage container 80 in and out of the vehicle 200 in cooperation with a transport mechanism that also serves as a loading / unloading mechanism for the vehicle 200. For example, the storage container 80 may include hooks, detents, sockets, and other physical structures configured to cooperate with the vehicle 200. In this example, the storage container 80 may include a retaining slot or groove 88 configured to cooperate with the loading / unloading element 212 of the vehicle 200. The retaining groove 88 may be formed below the lower side of the storage container 80 and below the bottom 83. The retaining groove 88 may be located behind the front face 84 of the storage container 80 as shown in FIGS. 11 and 13. The retaining groove 88 may extend so as to span the entire width of the storage container 80. Also, as shown in FIGS. 11 and 13, the groove 88 may have open ends on both side walls 82 such that the retaining groove 88 becomes a through groove. As shown in FIG. 13, the retaining groove 88 may be deeper than the thickness of the loading / unloading element 212 of the vehicle 200, and when the loading / unloading element 212 moves horizontally, the loading / unloading element 212 may be nested within the retaining groove 88B and drive the storage container 80 inward or outward. In addition, the storage container 80 may include a retaining groove 88 formed by a second groove or slot near the rear wall 86. The second retaining groove 88 may be configured substantially the same as the first wall, and may be formed in the vicinity of the rear wall 86 and located in front of the rear wall 86.

[0063] Referring to FIGS. 13 and 14, a releasable connector 90 for releasably connecting adjacent storage containers 80A and 80B is shown. By using the connector 90, the movement of the storage container 80 from the remote storage location 57 to the inner storage location 55 can be facilitated. The releasable connector 90 may be a cooperating hook or latch. For example, the releasable connector 90 may be formed from a pair of cooperating front connectors 92B and rear connectors 96A. The front connector 92B may be connected to the front end 84 of the storage container 80, and the rear connector 96A may be connected to the rear end 86 of the storage container 80. In this way, the front connector 92B of the first storage container 80B can be releasably connected to the rear connector 96A of the second storage container 80A to connect the two storage containers 80A and 80B. The front connector 92B is a tongue-shaped hook that extends substantially vertically downward (see 92B in FIG. 14). The front connector 92B projects downward from a recess adjacent to the front end 84 of the storage container 80. In this example, the front connector 92B is an L-shaped bracket. The L-shaped bracket may have a main body portion fixedly connected to the bottom 83 of the storage container 80. For example, the main body portion of the front connector 92B may extend substantially horizontally and may be fixed to the storage container 80 by a fastener that extends into the storage container 80 through the connector 92. The tongue portion 94 of the front connector 92B may protrude across the body portion so that the tongue portion forms a vertical hook or flange that engages with the second connector 96 by protruding downward. As shown in FIG. 13, the front connector 92B may be connected to the storage container 80 in front of the holding groove 88. The holding groove 88 is used to engage with the loading / unloading mechanism 212 of the vehicle 200.

[0064] The second connector 96, which consists of a rear connector, may be a second hook that cooperates with the first hook 92. The rear connector 96 may protrude rearward from the rear end portion 86 of the storage container 80. In this example, the second connector 96, which consists of a rear connector, incorporates a hook or flange that protrudes vertically upward. Specifically, the second connector 96 may include a groove or channel 98 configured to receive the tongue portion 94 of the first connector 92. The channel 98 may be connected to the rear end portion 86 of the storage container 80 such that the channel 98 protrudes rearward from the rear end portion 86. The second connector 96 may have a body portion fixedly connected to the bottom 83 of the storage container 80. For example, the body portion of the rear connector 96 is a substantially horizontally extending flat portion and may be fixed to the storage container 80 by a fastener extending into the storage container 80 through the rear connector 96.

[0065] As shown in FIG. 13, the tongue portion 94B of the front connector 92B of the first storage container 80B is inserted into the slot 98A of the rear connector 96A of the second storage container 80A to connect the first storage container 80B and the second storage container 80A. As will be further described below, the connection between the two storage containers 80A, 80B enables these storage containers 80A, 80B to move together when one of the storage containers 80 moves. In this way, when the first storage container 80B is pulled from the inner storage location 55 onto the vehicle 200, the storage container 80A connected thereto is pulled from the remote storage location 57 toward the inner storage location 55. <Track>

[0066] As can be understood from FIGS. 1 and 12, the track 110 may be arranged adjacent to the storage location 50 and direct the vehicle 200 toward the storage location 50. The track 110 may include a front track 115 and a rear track 120. The front track 115 and the rear track 120 are parallel tracks that guide the vehicle 200 along the track 110. As shown in FIG. 3, each vehicle 200 includes a total of four wheels 220, two front wheels and two rear wheels. The front wheels 220 ride on the front track 115, and the rear wheels 220 ride on the rear track 120. In the description of the track 110, it should be understood that the front track 115 and the rear track 120 are opposing tracks that are similarly configured to support the front wheels 220 and the rear wheels 220 of the vehicle 200. Therefore, the description of either part of the front track 115 or the rear track 120 also applies to the opposing front track 115 or rear track 120.

[0067] Referring to FIGS. 4 to 7, the track 110 will be described in more detail. However, as described above, the illustrated track 110 is only a track that can be used with the material handling system. The exact configuration may vary depending on the application, and as described above, the material handling system 10 may not include the track 110.

[0068] The track 110 may include an outer wall 152 and an inner wall 154 that is spaced parallel from the outer wall 152. Furthermore, the track 110 may include a rear wall 160 that extends between the inner wall 154 and the outer wall 152. As can be seen from FIG. 7, the outer wall 152, the inner wall 154, and the rear wall 160 form a channel. The wheel 220 of the vehicle 200 rides on this channel.

[0069] The track 110 may include a drive surface 156 and a guide surface 158. The drive surface 156 actively engages the vehicle 200 to enable the vehicle 200 to move along the track. The guide surface 158 guides the vehicle 200 and maintains an operable engagement between the vehicle 200 and the drive surface 156. In this example, the drive surface 156 is formed by a series of teeth that form a rack that engages the wheels of the vehicle 200, as will be further described below. The guide surface 158 is a substantially flat surface adjacent to the rack 156. The rack 156 extends for approximately half of the track 110, and the guide surface 158 extends for the other half of the track 110. As shown in FIGS. 4 to 7, the rack 156 may be formed on the inner wall 154 of the track 110. The opposing outer wall 152 may be a substantially flat surface parallel to the guide surface 158 of the inner wall.

[0070] As described above, the track 110 may include a plurality of vertical sections extending between the upper horizontal rail 135 and the lower horizontal rail 140. An intersection 170 may be formed at each section of the track 110 where any vertical section intersects any horizontal section. Each intersection 170 may include a curved inner branch 172 and a substantially straight outer branch 176. The portions where the vertical sections intersect the lower rail include similar intersections 170, but these intersections 170 are inverted.

[0071] Each intersection 170 may include a pivotable gate 180 having a smoothly curved inner race and a flat outer race with teeth corresponding to the teeth of the drive surface 156 of the track 110. The gate 180 may pivot between a first position and a second position. In the first position, the gate 180 is closed, and the straight outer race 184 of the gate 180 aligns with the straight outer branch 176 of the intersection 170. In the second position, the gate 180 opens, and the curved inner race 182 of the gate 180 aligns with the curved branch 172 of the intersection 170.

[0072] Thus, in the closed position, the gate 180 pivots downward so that the outer race 184 of the gate 180 aligns with the drive surface 156. In this position, the gate 180 prevents the vehicle 200 from turning downward at the bend, so the vehicle 200 travels straight through the intersection 170. In contrast, as shown in FIG. 5, when the gate 180 pivots to the open position, the gate 180 prevents the vehicle 200 from traveling straight through the intersection 170. Instead, the curved inner race 182 of the gate 180 aligns with the curved surface of the inner branch 172, and the vehicle 200 turns at the intersection 170. In other words, when the gate 180 is closed, depending on the position of the intersection 170, the vehicle 200 travels straight through the intersection 170 along either the upper rail 135 or the lower rail 135. When the gate 180 is open, depending on the position of the intersection 170, the gate 180 sends the vehicle 200 from the vertical rail 130 to the horizontal rail 135, or from the horizontal rail 135 to the vertical rail 130.

[0073] In the above description, the gate 180 causes one of the vehicles 200 to continue moving in the same direction (e.g., the horizontal direction) or turn in one direction (e.g., the vertical direction). However, in some applications, the material handling system 10 may include three or more horizontal rails 135 that intersect the vertical column. In such a configuration, it may be desirable to include different rails that cause the vehicle 200 to turn in multiple directions. For example, when the vehicle 200 is moving downward along the column, the gate 180 may be able to bend the vehicle 200 leftward or rightward along the horizontal rail 135, or move it straight along the vertical column. In addition, in some examples, the vehicle 200 may move upward.

[0074] Since the material handling system 10 includes a plurality of vehicles 200, the positions of the vehicles 200 are controlled so that the vehicles 200 do not collide with each other. In an embodiment, the material handling system 10 uses a central control device that tracks the position of each vehicle 200 and provides a control signal to each vehicle 200 to control the movement along the track 110 of the vehicle 200. The central control device may also control the operation of various elements along the track 110, such as the gate 180. Alternatively, the vehicle 200 may operate the gate 180. As shown in FIGS. 4 to 5, the gate 180 may include a passive actuator 190 that responds to the actuator 230 on the vehicle 200. When the actuator of the vehicle 200 engages the gate actuator 190, the gate 180 moves from the first position to the second position. For example, as shown in FIG. 4, the gate 180 takes the first position to keep the vehicle 200 along the horizontal rail 135. When the gate actuator 230 of the vehicle 200 engages the actuator 190 of the gate 180, the gate 180 pivots upward to the second position, and the vehicle 200 changes direction and moves downward along the vertical rail 130.

[0075] The actuator 190 on the gate 180 may be a movable operating surface 192 connected to the gate 180 by a linkage. For example, the operating surface 192 may be attached to a pivotable arm 193. To operate the gate 180 to move from the first position to the second position, the gate actuator 230 of the vehicle 200 contacts the operating surface 192. The actuating surface 192 is angled like an inclined surface, and as the vehicle 200 moves forward towards the gate 180, the gate actuator of the vehicle 200 engages with the actuating surface 192 and gradually moves the arm 193 upward. The arm 193 may be connected to the gate 180 by a linkage. Therefore, when the arm 193 pivots, the gate 180 also pivots. In this way, as shown in FIGS. 4 to 5, the actuator 230 of the vehicle 200 engages with the actuator on the gate 180 and moves the gate 180 from the first position to the second position. After the vehicle 200 passes through the open gate 180 as shown in FIG. 5, the gate 180 may return to the closed position shown in FIG. 4. The gate 180 may close automatically by a biasing element or the weight of the gate 180 and / or the actuator, etc. <Transport vehicle>

[0076] Referring to FIG. 3, the details of the vehicle 200 serving as a transport vehicle will be described in detail. Each transport vehicle 200 is a semi-automatic vehicle that may be equipped with an on-vehicle drive system including an on-vehicle power source. Each vehicle 200 may also be equipped with a mechanism 210 for loading and unloading items to be transported. Optionally, each vehicle 200 may also be equipped with a gate actuator 230 that selectively actuates the gate 180 to selectively change the direction of the vehicle 200.

[0077] The vehicle 200 may include any of various mechanisms for loading items onto the vehicle 200 and discharging items from the vehicle 200 into any container. In addition, the loading / unloading mechanism 210 may be specially adjusted for a specific application. The loading / unloading mechanism 210 may include a movable element configured to engage an item stored in a storage location and draw the item into the vehicle 200. In this example, the vehicle 200 includes a movable element configured to move toward the storage container 80 of the storage location 50. After engaging with the storage container 80, the movable element moves away from the storage location 50, thereby pulling the storage container 80 into the vehicle 200.

[0078] In this example, the loading / unloading mechanism 210 may include a loading / unloading element 212 consisting of a movable rod or bar. The bar 212 extends across the width of the vehicle 200 and may have both ends connected to a drive chain 214 that extends along the side of the vehicle 200. A motor may drive the drive chain 214 to selectively move the drive chain 214 in a direction toward or away from the storage location 50. For example, when the vehicle 200 approaches the storage location to acquire the storage container 80, the drive chain 214 drives the loading / unloading element 212 consisting of a rod toward the storage location 50, thereby engaging the bar 212 with a retaining groove 88 consisting of a groove or notch in the bottom 83 of the storage container 80. Thereafter, the drive chain 214 reverses, thereby moving the loading / unloading element 212 consisting of a bar away from the storage location 50. Since the loading / unloading element 212 consisting of a bar is engaged with the notch 88 of the storage container 80, when the bar 212 moves away from the storage location 50, the bar 212 pulls the storage container onto the vehicle 200. Thereby, the loading / unloading mechanism 210 can acquire an item from the storage location 50. Similarly, to store an item in the storage location 50, the drive chain 214 of the loading / unloading mechanism 210 drives the bar 212 toward the storage location 50 until the item is positioned within the storage location 50. Thereafter, the vehicle 200 may move downward to disengage the bar 212 from the storage container 80, thereby releasing the storage container. Alternatively, the loading / unloading mechanism 210 may be configured to disengage from the notch 88 and drive the bar 212 downward.

[0079] In addition, since the material handling system 10 includes an array of storage locations 50 adjacent to the front side of the track 110 and a second array of storage locations 50 adjacent to the rear side of the track 110, the loading / unloading mechanism 210 is operable to acquire and store the storage containers 80 within the front side array and the rear side array. Specifically, as shown in FIG. 3, the loading / unloading mechanism 210 includes two bars 212 spaced apart from each other. One bar 212 is engageable with the storage container 80 of the front array, while the second bar 212 is engageable with the storage container 80 of the rear array of the storage location 50.

[0080] The vehicle 200 may include four wheels 220 used to transfer the vehicle 200 along the track 110. The wheels 220 may be attached to two parallel and spaced-apart shafts 215 such that two wheels are installed along the front end of the vehicle 200 and two wheels are installed along the rear end of the vehicle 200.

[0081] The vehicle 200 may include an on-vehicle motor that drives the wheels 220. More specifically, the drive motor may be operably connected to the shaft 215 to rotate the shaft, thereby rotating the gears 222 of the wheels 220. The drive system of the vehicle 200 may be configured to drive the vehicle 200 synchronously along the track 110. In this example, the drive system is configured such that each gear 222 is driven in a synchronous manner.

[0082] The vehicle 200 can also be moved by an external power source, such as a rail contact that provides the power necessary to drive the vehicle 200. However, in this example, the vehicle 200 includes an on-vehicle power source that provides the power necessary for both the drive motor and the motor that drives the loading / unloading mechanism 210. Furthermore, in this example, the power source is rechargeable. The power source may include a power source such as a rechargeable battery, but in this example, the power source is composed of one or more ultracapacitors. Ultracapacitors can accept and recharge extremely high amperages. By using a high current, the ultracapacitor can be recharged in an extremely short time, such as within a few seconds or less.

[0083] The vehicle 200 includes one or more contacts for recharging the power source. In this example, the vehicle 200 includes a plurality of brushes, such as spring-loaded copper brushes, that are biased outward. The brushes recharge the power source in conjunction with the charging rail.

[0084] Each vehicle 200 may include a loading sensor that detects when an item has been loaded onto the vehicle 200. By using this loading sensor, it is possible to detect whether an item is properly placed on the vehicle 200. For example, the loading sensor may include a force detector that detects a change in weight or an infrared sensor that detects the presence of an item.

[0085] The vehicle 200 may further include a processor that controls the operation of the vehicle 200 in response to a signal received from the central processor of the material handling system. Furthermore, the vehicle 200 may include a wireless transceiver that enables continuous communication with the central processor when the vehicle 200 moves along the track 110. Alternatively, in some applications, it may be desirable to incorporate a plurality of sensors or indicators arranged along the track. Vehicle 200 may include a reading device that senses sensor signals and / or indicators, and a central processor that controls the operation of vehicle 200 according to the sensors or indicators. <Collection Location and Track>

[0086] As described above, the material handling system 10 may be configured such that the vehicle 200 acquires an item from the storage location 50 and transfers the item to the collection location 300. Here, referring to FIGS. 1 to 2, the collection location 300 will be described in more detail.

[0087] The system 10 is used to acquire the items necessary for order fulfillment. The order may be an internal order such as parts required for the manufacturing process in different departments, or a customer order to be fulfilled and shipped to the customer. In either case, the material handling system 10 automatically acquires items from the storage area, transports the items to the collection location 300, and enables the operator to collect the required number of items from the storage container 80. After the item is collected from the storage container 80, the vehicle 200 moves forward and advances to the next item required for the order. The material handling system 10 continues to operate in this manner to enable the operator to collect all the items required for the order.

[0088] In this example, the collection location 300 is arranged at one end of the array of the storage location 50. However, it may be desirable to arrange a plurality of collection locations 300 along the track 110. For example, a second collection location 300 can be arranged along the other end of the array of the storage location 50. Alternatively, a plurality of collection locations 300 can be provided at one end. For example, the second collection location 300 may be located above the first collection location 300 at one end of the passage 20.

[0089] The collection station 300 may be configured such that the vehicle 200 moves upward to present the contents to the operator, thereby enabling the operator to easily obtain items from the storage container 80. Referring to FIGS. 1 to 2, in the collection station 300, the track 110 includes a curved section 315 that curves upward and is spaced apart from the operator. Thereby, the vehicle 200 moves upward and stops at a height at which it is easy for the operator to take out items from the storage container 80. After the operator takes out an item from the storage container 80, the vehicle 200 moves laterally away from the operator and vertically toward the upper horizontal rail 135.

[0090] The material handling system can be configured such that the vehicle 200 tilts at the collection station 300, thereby facilitating the operator's acquisition of items from the storage container 80. For example, when the vehicle 200 approaches the collection station 300, the control device can control the vehicle 200 such that the rear wheels 220 continue to move even after the front wheels 220 stop. Thereby, the rear end of the vehicle 200 is lifted (from the operator's perspective). After the operator collects an item from the storage container 80, the front wheels 220 first move (with respect to the operator) to level the vehicle 200. After leveling, the four wheels 220 are driven synchronously.

[0091] Although it is possible to tilt the vehicle 200 by controlling the operation of the vehicle 200, if the wheels of the vehicle 200 are firmly engaged with the driving elements of the track 110, such as the toothed wheels 220 that engage with the teeth of the track 110 as described above, the wheels 220 may become immovable if the rear wheels 220 are driven at a different speed from the front wheels 220. Therefore, the track 110 may be improved such that the track system moves to tilt the storage container toward the operator.

[0092] Referring to FIGS. 1 and 2, the details of the track system at the collection station 300 will be described in more detail. At the end of the column of the storage location 50, the track 110 curves outward from the vertical column of the system to form the curved track 315 of the collection station 300. This track section of the collection station 300 includes a parallel front track section that supports and guides the front axle 215 of the vehicle 200, and a parallel rear track section that supports and guides the rear axle 215 of the vehicle 200. The front track section extends vertically upward and then curves back to the vertical column of the storage location. The rear track section is substantially parallel to the front track section and curves in substantially the same manner as the front track section. Thereby, the front track section and the rear track section guide the vehicle 200 so that the vehicle 200 can maintain a substantially horizontal orientation when moving along the curved track 315.

[0093] The rear track section may be configured to raise the rear axle of the vehicle 200 while the vehicle 200 is stopped at the collection station 300. By raising the rear axle of the vehicle 200, the storage container 80 of the vehicle 200 is tilted, and the contents of the storage container are presented to facilitate the collection operation of the operator.

[0094] The collection station 300 may include a plurality of items to improve the efficiency of the collection station 300. For example, the collection station 300 may include a monitor for displaying information to assist the operator. When the vehicle 200 approaches the collection station 300, the material handling system 10 may display information such as the number of items that need to be retrieved from the storage container 80 for the order. In addition, since the operator may retrieve items for multiple orders, the system may display the order for the items to be retrieved in addition to the number of items that need to be retrieved for each order. Furthermore, the material handling system may also display information such as the number of items that should remain in the storage container after the operator has retrieved an appropriate number of items from the storage container.

[0095] One of the advantages of the material handling system described above is that when the vehicle 200 transitions from horizontal movement (along an upper rail or a lower rail) to vertical movement (descending one of the columns), the orientation of the vehicle 200 does not substantially change. Specifically, when the vehicle 200 is moving horizontally, the two front toothed wheels 220 cooperate with the upper horizontal rail 135 or the lower horizontal rail 140 of the front track 115, and the two rear toothed wheels 220 cooperate with the corresponding upper rail 135 or lower rail 140 of the rear track 120. When the vehicle 200 passes through the gate and enters the column, the two front toothed wheels 220 engage with a pair of vertical sections 130 of the front track 115, and the two rear toothed wheels engage with the corresponding vertical sections of the rear track 120. Note that the fact that the orientation of the vehicle 200 does not change in the horizontal direction means that the vehicle 200 moves along the track 110. Even if the vehicle 200 is inclined with respect to the horizontal direction at the collection point 300, it can be said that the vehicle 200 maintains a substantially constant orientation with respect to the horizontal direction when moving along the track 110.

[0096] When the vehicle 200 moves from the upper horizontal rail 135 or the lower horizontal rail 140 to the vertical column, or from the vertical column to the upper horizontal rail 135 or the lower horizontal rail 140, the track 110 positions all four toothed wheels 220 at the same height. Thereby, when the vehicle 200 moves along the track 110 and transitions between horizontal movement and vertical movement, it does not become distorted or inclined. In addition, it may be desirable to configure the vehicle 200 with a single axis. In such a configuration, the vehicle 200 assumes a substantially vertical orientation instead of the substantially horizontal orientation described above. In a single-axis configuration, the orientation of the vehicle 200 is maintained by the weight of the vehicle 200. However, when using the single-axis vehicle 200, the orientation of the storage location 50 is reconfigured according to the vertical orientation of the vehicle 200. <Operation>

[0097] When the central control device determines the appropriate storage location 50 for the item, the route of the vehicle 200 leaving the collection point 300 may be determined. Specifically, the central control device may determine the route of the vehicle 200 and transmit information regarding the storage location 50 of the delivery destination of the item to the vehicle 200. Next, the central control device controls the operation of the vehicle 200 and operates the gate 180 along the track 110, which is necessary to direct the vehicle 200 towards the storage location 50 that is the delivery destination of the item. When the vehicle 200 arrives at the appropriate storage location 50, the vehicle 200 stops at the storage location 50, and the storage container 80 moves to the appropriate storage location 50. For example, when the vehicle 200 stops at the appropriate storage location 50, the in-vehicle controller on the vehicle 200 may send an appropriate signal to the vehicle 200 to drive the drive chain 214 that advances the bar 212. Since the bar 212 engages with the slot 88 of the storage container 80, the bar 212 drives the storage container 80 in a direction away from the vehicle 200 and drives it to the appropriate storage location 50.

[0098] After discharging the item, the vehicle 200 may move to the second storage location and acquire the next item to be transported to the collection point 300. After acquiring the item, the vehicle 200 may move downward through the vertical section 130 of the column and reach the lower rail 140. The gate 180 may send the vehicle 200 along the lower rail 140, and the vehicle 200 may follow the lower rail 140 back to the collection point 300 to deliver another item.

[0099] When the vehicle 200 delivers the storage container 80 to an empty storage location, the vehicle 200 operates as described above. Similarly, when the vehicle 200 acquires a storage container 80 that is not connected to another storage container 80, the vehicle 200 operates as described above. Specifically, the vehicle 200 stops adjacent to the storage container. After the loading / unloading mechanism 210 moves forward and engages with the storage container 80, the storage container 80 is pulled onto the vehicle 200. Conversely, when the vehicle 200 transports a storage container 80 that is already placed in a storage location 50 that houses the storage container 80, the operation of the vehicle 200 is changed. Similarly, when the vehicle 200 is acquiring a storage container 80 that is connected to a storage container 80 at a remote storage location 50, the operation of the vehicle 200 is changed.

[0100] Here, with reference to FIGS. 9 and 10A to 10H, the operation of the vehicle 200 when acquiring the storage container 80 from a storage location 50 having a depth for "n" storage containers will be described. FIG. 9 shows an embodiment in which two storage racks 35 and 40 of the storage container 80 are shown. The storage racks 35 and 40 are separated from each other by a passage 20, and the vehicle 200 moves within the space between the storage rack 35 and the storage rack 40. In the illustrated embodiment, the storage rack includes a storage location 50 having a depth sufficient to store two storage containers 80. In this description, the portion of the storage location 50 adjacent to the passage 20 that houses the storage container 80 is referred to as the inner cell and is denoted by 55. The portion of the storage location 50 behind the inner cell 55 is referred to as the remote cell and is denoted by 57.

[0101] In the illustrated embodiment, the storage containers 80A and 80B include a front connector 92 connected to the front end portion of the storage container 80 and a rear connector 96 connected to the rear end portion of the storage container 80. The front connector 92 of the storage container 80B in the remote cell is connected to the rear connector 96 of the storage container 80A in the inner cell to form a releasable connection indicated by 90.

[0102] In FIG. 9, the storage container 80B is stored in a remote cell behind the storage container 80A stored in the inner cell. The storage container 80A and the storage container 80B are releasably connected to each other by a connector such as the connector 90. The storage container 80A and the storage container 80B are generally aligned when viewed from the horizontal direction. The vehicle 200 stops at a position adjacent to the storage location 50 that houses the first storage container 80A. The vehicle 200 is empty (i.e., the storage container 80 is not mounted on the vehicle 200). As shown in FIG. 9, the loading / unloading mechanism 210 engages with the storage container 80A. For example, as shown in FIGS. 11 and 12, the front end portion of the storage container 80 may extend into the passage 20 beyond the track (for example, the vertical track section 130). Specifically, the transport groove 88 of the storage container 80 may extend into the passage 20. The loading bar 212 extends outwardly toward the storage container 80 away from the platform of the vehicle 200 until the loading bar 212 is inserted into the transport groove 88.

[0103] Referring to FIG. 10A, the loading mechanism 210 pulls the storage container 80A onto the vehicle 200. When the storage container 80A in the inner cell is pulled onto the vehicle 200, the storage container 80A pulls the second storage container 80B in the remote cell toward the inner cell. Specifically, since the connector 90 connects the storage container 80A in the inner cell and the storage container 80B in the remote cell, the storage containers move horizontally together.

[0104] Referring to FIG. 10B, until the storage container 80A moves away from the storage container 80 in the storage location above it, the vehicle 200 continues to move the storage container 80A onto the platform of the vehicle 200. As the storage container 80A moves, the remote storage container 80B is drawn into the inner cell. As a result, the storage container 80B occupies the location in the storage rack that was occupied by the storage container 80A. In FIG. 10B, it can be seen that by drawing the storage container 80B into the inner cell, the remote cell 57 behind the storage container 80B is empty.

[0105] As described above, the loading mechanism 210 of the vehicle 200 loads the inner storage container 80A onto the vehicle 200 and then horizontally moves the remote storage container 80B until the remote storage container 80B moves to a different storage location (in this case, the inner cell). Continuing to move the storage container 80A onto the vehicle 200, since the two storage containers 80A and 80B remain connected, the storage container 80B is drawn into the passageway and, in some cases, onto the vehicle 200. Therefore, when the storage container 80B is moved to the new storage location (i.e., the inner cell), the releasable connection 90 is disconnected, thereby separating the two storage containers 80A and 80B.

[0106] The storage containers 80A and 80B may be separated in various ways depending on the mechanism that interconnects these storage containers 80A and 80B. As described above, the connectors 92 and 96 may be any of various connectors that provide a releasable connection between the two storage containers 80A and 80B. The connector may be mechanical or electromechanical. For example, the connectors 92 and 96 may be magnetic elements, and one of them may include an electromagnet. The electromagnet may facilitate the relative movement of the storage container 80A with respect to the storage container 80B by demagnetizing and separating the storage containers 80A and 80B. Alternatively, as described above, the connectors 92 and 96 may be mechanical connectors such as a pair of hooks or a configuration of a tongue and groove. Therefore, in order to separate the storage containers 80A and 80B, the engagement of the connectors 92 and 96 is released. In the embodiment, the engagement of the connectors 92 and 96 is released by vertically displacing one of the storage containers 80 with respect to the other storage container 80.

[0107] Referring to FIG. 10C, when the storage container 80A is loaded onto the vehicle 200 and the storage container 80A moves away from the storage container 80 directly above or below in the column, the storage container 80A moves vertically to separate the storage container 80A from the storage container 80B. As shown in FIGS. 13 to 14, the tongue 94B of the connector 92B may project downward into the groove 98A of the connector 96A. Therefore, as shown in FIG. 14, until the tongue 94B of the connector 92B disengages from the groove 98A, the vehicle 200 moves downward to move the storage container 80A vertically downward. In this way, when the vehicle 200 is displaced, the storage container 80A is vertically separated from the storage container 80B. It should be understood that the connectors 92 and 96 can have different configurations such that the connectors are separated by moving the vehicle 200 upward instead of lowering the vehicle 200.

[0108] Here, referring to FIG. 10D, after the storage container 80A is separated from the storage container 80B, the storage container 80A moves horizontally on the vehicle 200 away from the storage container 80B. When the vehicle 200 moves vertically up and down within the column, the storage container 80A moves horizontally until it reaches the center within the passage 20 so that the storage container 80 does not interfere with or engage any of the vehicles 200 within the storage rack. Once the storage container 80A is fully loaded onto the vehicle 200, the vehicle 200 may proceed to the collection point 300 or other transportation locations, or to different storage locations. For example, the vehicle 200 may lower to the lower horizontal rail and then move along the horizontal rail to deliver the storage container 80A to the collection point 300. Alternatively, the storage container 80A may be transferred to another storage location and loaded and unloaded at that storage location.

[0109] Details of the step of loading and unloading the storage container 80A on the vehicle 200 to the storage location where the storage container 80C is located will be described below in relation to FIGS. 10E to 10H. The vehicle 200 moves to a position adjacent to the inner cell of the storage rack 40 where the storage container 80C is stored. The storage container 80A is loaded and unloaded from the vehicle 200 to the storage container 80C. Once the storage container 80A is loaded and unloaded, the storage container 80A pushes the storage container 80C deeper into the storage location within the storage rack. By doing so, the storage container 80C moves horizontally from the inner cell to the remote cell 57. During the process of unloading the storage container 80A and moving the storage container 80C, the storage container 80A is connected to the storage container 80C. As described above, the connectors of the two storage containers 80A and 80C may be connected in various ways. In this example, the storage containers 80A and 80C are connected by moving one of the storage containers 80 with respect to the other. Specifically, the two storage containers 80A and 80C are connected by the vertical displacement of the storage container 80A with respect to the storage container 80C.

[0110] Referring again to FIG. 10E, in order to load and unload the storage container 80A, the vehicle 200 moves along the track until the storage container 80A is disposed vertically higher than the storage container 80C. Specifically, the vehicle 200 is driven to a position adjacent to the storage container 80 such that the front connector 92 of the storage container 80A is positioned above the rear connector 96 of the storage container 80C. Next, as shown in FIG. 10F, by horizontally moving the storage container 80A toward the storage container 80C, the vehicle 200 partially unloads the storage container 80. In this example, the storage container 80A is moved until the front connector 92 of the storage container 80A follows the rear connector 96 of the storage container 80C. Specifically, the loading / unloading mechanism 210 of the vehicle 200 horizontally moves the storage container 80A until the tongue portion 94 of the front connector 92 follows the groove 98 of the rear connector 96 of the storage container 80C.

[0111] When the connectors of the storage container 80A and the storage container 80C are aligned, the vehicle 200 moves vertically to connect the storage containers 80. Specifically, referring to FIG. 10G, the vehicle 200 moves downward to horizontally align the storage container 80A and the storage container 80C and interconnect the two storage containers 80A and 80C. When the storage container 80A is horizontally aligned with the storage location, as shown in FIG. 10H, the storage container 80A is unloaded from the vehicle 200 to the storage location. For example, in the present embodiment, the loading / unloading mechanism 210 of the vehicle 200 moves the first storage container 80A from the vehicle 200 and moves it to the inner cell where the third storage container 80C was disposed. When the storage container 80A is moved into the inner cell, the storage container 80A pushes the storage container 80C deeper into the storage location, and the storage container 80C moves into the remote cell (shown at 57 in FIG. 10G).

[0112] As described above, the storage container 80A is moved to a position adjacent to the storage container 80C. And before loading and unloading the storage container 80A onto the storage rack, the two storage containers 80A and 80C are connected. In this way, then, when the storage container 80A is subsequently retrieved, the storage containers 80A and 80C are connected so that the storage container 80C in the remote cell can be pulled toward the passage 20 (see, for example, FIGS. 10A to 10D and the above description). However, it should be understood that it is not necessary to connect the storage container 80 in order to unload the storage container 80A and move the storage container 80C to the remote cell. Specifically, since the storage container 80A pushes the storage container 80C backward into the rear cell, it is not necessary to connect the storage container 80 before unloading the storage container 80A. Therefore, depending on the configuration of the front connector 92 and the rear connector 96, the storage containers 80 may be connected to each other after the first storage container 80A is unloaded from the vehicle 200.

[0113] Therefore, as described above, the material handling system may be configured to incorporate storage locations having a plurality of depths. In the storage locations having a plurality of depths, a plurality of storage containers 80 are stored one behind the other in a common horizontal storage location. The storage containers 80 in the common horizontal storage location may be interconnected, and when one of the storage containers 80 in the common storage location is retrieved, the other storage containers 80 in the common storage location move forward toward the vehicle 200. In the above description, the operation in which the storage container 80A is loaded onto the transport vehicle, whereby the storage container 80 is pulled from the remote cell into the inner cell so that the storage container 80 can be retrieved from the inner cell has been described. Thereafter, the vehicle 200 delivers the storage container 80A to another storage location and can then retrieve the storage container 80B that has returned and moved into the inner cell. Alternatively, in certain instances, the storage location for two storage containers 80A, 80B (such as storage containers 80A and 80B shown in FIG. 9) may be located on the opposite side of an empty storage location that is vertically and horizontally aligned with the two storage containers 80. In such a case, storage container 80A may be loaded onto vehicle 200, thereby pulling storage container 80B onto vehicle 200. As described above, rather than separating the two storage containers 80, storage container 80A is further moved horizontally to load and unload storage container 80 into the storage location of the opposing storage rack. When storage container 80A is loaded and unloaded into the storage location, storage container 80B is pulled onto vehicle 200. Next, storage container 80B can be separated from storage container 80A so that vehicle 200 can deliver storage container 80B to a collection point or another storage location. For example, vehicle 200 can be moved vertically to separate storage container 80B from storage container 80A.

[0114] In the foregoing description, a material handling system in which storage container 80 is stored in a storage location with multiple depths has been described. The storage container 80 at a remote location in the storage location with multiple depths may be acquired by vehicle 200 that first acquires the storage container 80 in front of the storage container 80 in the remote cell. The acquired storage container 80 is then transferred by vehicle 200. The acquired storage container 80 may then be stored in another location, and vehicle 200 may return to acquire the storage container 80 that was in the remote cell. Alternatively, a first vehicle may acquire the storage container 80 in front of the storage container 80 in the remote cell, and a second vehicle may come to acquire the storage container 80 that was located in the remote cell.

[0115] Without departing from the broad inventive concept of the present invention, changes or modifications can be made to the above-described embodiments. Therefore, the present invention is not limited to the embodiments described in this specification and includes all changes and modifications within the scope of the claims. Brief Description of the Reference Numerals

[0116] 10 ··· Material handling device 20 ··· Passageway 35 ··· Storage rack 40 ··· Storage rack 50 ··· Storage location 52 ··· Horizontal support element 55 ··· Inner storage location 57 ··· Outer storage location 80 ··· Storage container 80A ··· Storage container (second storage container) 80B ··· Storage container (first storage container) 83 ··· Bottom 84 ··· Front wall (front surface, front end) 86 ··· Rear wall (rear end) 88 ··· Holding groove (notch) 90 ··· Connector 92 ··· Front connector (first hook, first connector) 94 ··· Tongue 96 ··· Rear connector (second connector 96) 98 ··· Channel (slot) 110 ··· Track 115 ··· Front track 120 ··· Rear track 130 ··· Vertical support (vertical section) 135 ··· Upper horizontal rail (upper rail) 140 ··· Lower horizontal rail (lower rail) 156 ··· Driving surface (rack) 158 ··· Guide surface 170 ··· Intersection 172 ··· Inner branch 176 ··· Outer branch 180 ··· Gate 190 ··· Passive actuator 192 ··· Actuating surface 193 ··· Arm 200 ··· Vehicle 210 ··· Loading / unloading mechanism 212 ··· Loading / unloading element (bar) 214 ··· Drive chain 215 ··· Shaft 220 ··· Wheel 222 ··· Gear 230 ··· Actuator 300 ··· Collection point (article transport point) 315 ··· Curved track

Claims

1. A material handling system for storing or retrieving a plurality of items, comprising: a plurality of vehicles each including an in-vehicle motor for driving each vehicle to deliver and retrieve the items using storage containers; a first rack at a storage location, and a second rack located away from the first rack and having a passage therebetween, wherein the plurality of vehicles are movable in the vertical and horizontal directions along a vertical circular path within the passage; a plurality of storage containers, each storage location accommodating a plurality of the storage containers and configured to transport the storage containers in and out of the vehicle by cooperating a holding groove provided at the bottom of the storage container with a bar provided on a loading / unloading element of the vehicle, a first one of the plurality of storage containers including a first connector provided in front of the holding groove at the bottom of a first front end portion, a second one of the plurality of storage containers including a second connector provided behind the holding groove at the bottom of a second rear end portion, and a tongue protruding downward from the first connector being releasably inserted into a slot of the second connector so that a first storage container which is the first one of the plurality of storage containers and a second storage container which is the second one of the plurality of storage containers are releasably connected at one of the storage locations, and each vehicle including a transport mechanism for transporting the first storage container and the second storage container between the vehicle and the one storage location, the transport mechanism being operable to horizontally move the second storage container when moving the first storage container; a central control device for directing a first vehicle among the plurality of vehicles toward the one storage location, transporting the first storage container onto the first vehicle to horizontally move the second storage container toward the passage, directing the first vehicle toward a second storage location among the plurality of storage locations, and transporting the first storage container to the second storage location before returning to the first storage location among the plurality of storage locations to retrieve the second storage container from the first storage location; A material handling system comprising the above.

2. The material handling system according to claim 1, further comprising a guide for guiding the plurality of vehicles along the vertical circular path.

3. comprising a track for guiding the plurality of vehicles, the track comprising: a plurality of horizontal track sections that are spaced apart from each other and generally extend in a horizontal direction; a plurality of vertical track sections that are spaced apart from each other and generally extend in a vertical direction, the vertical track sections intersecting the horizontal track sections to form an annular path; an intersection where one of the horizontal track sections intersects one of the vertical track sections, the intersection providing a first path generally in the horizontal direction and a second path generally in the vertical direction, the material handling system according to claim 1.

4. The material handling system according to claim 1 or claim 2, wherein the connection between the first connector and the second connector prevents horizontal movement of the first storage container relative to the second storage container.

5. The material handling system according to claim 4, wherein the connection between the first connector and the second connector is sufficient to support the weight of the second storage container during horizontal movement, such that when the first connector and the second connector are connected, horizontal movement of the first storage container causes the second storage container to move horizontally.

6. The material handling system according to claim 4 or claim 5, wherein the connection between the first connector and the second connector permits vertical movement of the first storage container relative to the second storage container.

7. The material handling system according to any one of claims 4 to 6, wherein the first connector and the second connector are configured such that vertical movement of the first connector relative to the second connector disengages the first connector from the second connector.

8. The material handling system according to any one of claims 1 to 7, wherein the first connector comprises a tongue portion and the second connector comprises a groove portion configured to receive the tongue portion.

9. The material handling system according to any one of claims 1 to 8, wherein the storage locations where the first storage container and the second storage container are located are configured to accommodate the first storage container and the second storage container following a horizontal direction, and the first storage container is disposed in front of the second storage container.

10. When one of the plurality of vehicles follows the first storage container, the first storage container separates the second storage container from one of the plurality of vehicles. The material handling system according to any one of claims 1 to 9.

11. One of the storage locations has a depth, each of the first storage container and the second storage container has a length, and the depth of the one storage location has a length at least as long as the total length of the first storage container and the second storage container. The material handling system according to any one of claims 1 to 10.

12. The plurality of vehicles includes a generally planar platform for accommodating the storage container. The material handling system according to any one of claims 1 to 11.

13. A collection point is arranged at an end of the passage, the plurality of vehicles deliver the storage container to the collection point, and an operator can obtain an item from the storage container at the collection point. The material handling system according to any one of claims 1 to 12.

14. The plurality of vehicles are provided with drive wheels engaged with the track, and the first rack and the second rack are positioned with respect to the track such that the storage container horizontally protrudes into the passage beyond the track. The material handling system according to claim 3.

15. The storage container includes one or more engagement elements configured to engage with the transport mechanism of the plurality of vehicles. The material handling system according to any one of claims 1 to 14.

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