Storage box transfer robot

Abstract

The present invention relates to a remotely operated vehicle suitable for picking up storage bins from an underlying storage system. The carrier comprises a driving means (19) located on or at least partially within the rolling means (10) of the carrier and providing a rolling set-specific driving force to the carrier in a first direction (X) or a second direction (Y).

Description

[Technical Field]

[0001] The present invention relates to a remotely operated vehicle or robot for picking up storage boxes from a storage system as defined in the preamble of claim 1, and to a storage system for storing the boxes. [Background technology]

[0002] Remotely operated vehicles are known for picking up storage bins from storage systems. A detailed description of a related prior art storage system is presented in WO 98 / 49075, and details of a prior art vehicle suitable for such a storage system are disclosed in detail in Norwegian Patent No. 0317366. Such prior art storage systems include a three-dimensional storage grid that accommodates storage bins stacked on top of one another to a certain height. The storage grid is typically constructed as an aluminum column interconnected by an upper rail, on which multiple remotely operated vehicles, or robots, are positioned for lateral movement. Each vehicle is equipped with a lift for picking up, transporting, and placing bins to be stored in the storage grid, and a rechargeable battery for powering the vehicle's integrated motor. The vehicles typically communicate with a control system via a wireless link and are recharged, when necessary, typically overnight, at a charging station.

[0003] An example of a prior art storage system is shown in Figure 1. The storage system 3 includes a plurality of transporters or robots 1 configured to move in X and Y directions (referring to a Cartesian coordinate system 100) on dedicated support rails 13 and to receive storage boxes 2 from storage rows in a box storage grid 15. The prior art storage system 3 may also include a dedicated box lift device 50 arranged to receive storage boxes 2 from the transporters 1 at the top level of the storage system 3 and transport the storage boxes 2 vertically downward to a delivery station or port 60.

[0004] However, in this known system, each transport covers a cross section equivalent to two storage rows of the underlying storage system, thereby limiting the maximum number of transports that can operate simultaneously. Summary of the Invention [Problem to be solved by the invention]

[0005] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a transport and storage system that allows for a significant increase in the number of transports operating simultaneously while still providing successful handling of storage bins. [Means for solving the problem]

[0006] The invention is set forth and characterized in the main claim, while further features of the invention are described in the dependent claims. In particular, the present invention relates to a remotely operated transport device for picking up storage bins from an underlying storage system, the remotely operated transport device comprising: a lifting device suitable for lifting the storage bins from the underlying storage system; a first transport rolling means comprising a first rolling set and a second rolling set arranged on opposite side walls of the transport body, the first rolling set and the second rolling set arranged on opposite side walls of the transport body, the second transport rolling means comprising the first rolling set and the second rolling set arranged on opposite side walls of the transport body, the second transport rolling means comprising the first rolling set and the second rolling set arranged on opposite side walls of the transport body, the second transport rolling means comprising the first rolling set and the second rolling set arranged on opposite side walls of the transport body, the second transport rolling means comprising the first rolling set and the second rolling set arranged on opposite side walls of the transport body, the second transport rolling means comprising the first rolling set and the second rolling set arranged on Any other mechanism or combination of mechanisms may also be included.

[0007] The transport further comprises first drive means located on or at least partially within the first transport rolling means and suitable for providing a rolling set specific drive force to the transport in a first direction (X), second drive means located on or at least partially within the second transport rolling means and suitable for providing a rolling set specific drive force to the transport in a second direction (Y), and motor control electronics located in a volume between two of the wheels of each rolling set, the motor control electronics configured to provide power to the first and second transport rolling means. In use, at least one of the first and second transport rolling means is in contact with the underlying storage system.

[0008] In an advantageous embodiment, at least one of the drive means comprises an electric motor using permanent magnets, such as a brushless electric DC (direct current) motor. In another advantageous embodiment, at least one of the first and second drive means comprises a rotor magnet arranged on an inner surface of the outer periphery of the corresponding respective carrier rolling means.

[0009] In another advantageous embodiment, at least one of the first and second drive means comprises a stator arranged at least partly, preferably completely, in the same plane of rotation as the carrier rolling means and at least partly, preferably completely, within the carrier body, whereby plane of rotation means a plane extending at right angles from the axis of rotation of the carrier rolling means.

[0010] In another advantageous embodiment, the vehicle comprises means suitable for (at least indirectly) measuring the electromotive force (emf) of at least one vehicle rolling means, in signal communication with one of the stator and rotor, thereby enabling rolling set-specific speed registration of the vehicle during operation. For example, a back-emf measuring circuit may be placed in signal communication with the vehicle rolling means. Alternatively, or in combination therewith, Hall sensors may be used.

[0011] In another advantageous embodiment, the vehicle comprises a rotary encoder (at least indirectly) connected to at least one of the first and second vehicle rolling means, thereby enabling angular position feedback during operation. Such a rotary encoder is suitable for converting the angular movement of the vehicle rolling means into an analog or digital code. The rotary encoder (or shaft decoder) can be of the absolute rotary encoder and / or absolute multi-turn encoder type. The absolute rotary encoder can be at least one of a mechanical encoder, an optical encoder, a magnetic encoder, and a capacitive encoder. Furthermore, the absolute multi-turn encoder can be at least one of a battery-powered multi-turn encoder, a gear-type multi-turn encoder, and a self-powered multi-turn encoder.

[0012] In another advantageous embodiment, the rotary encoder is a rotary encoder disc arranged within the outer periphery of at least one of the first and second carrier rolling means, preferably between the outer periphery and the rotor magnet.

[0013] In another advantageous embodiment, the vehicle further comprises means in signal communication with the stator suitable for measuring the acceleration of at least one of the first and second vehicle rolling means. Such means preferably comprise one or more piezoelectric sensors, for example accelerometers from PCB™ Piezotronics. As an alternative to piezoelectric sensors , or in combination with a piezoelectric sensor, one or more inductive sensors may be used.

[0014] In another advantageous embodiment, each rolling set comprises at least two wheels, and the vehicle further comprises motor control electronics arranged in a volume between two of the wheels of each rolling set, said motor control electronics being in this embodiment configured to provide power to the first and second vehicle rolling means and preferably also capable of transmitting communication signals.

[0015] In another advantageous embodiment, the first vehicle rolling means comprises four X-wheels with a first direction of rotation, and the second vehicle rolling means comprises four Y-wheels with a second direction of rotation, each of the X-wheels and each of the Y-wheels being drivingly connected to the first drive means and the second drive means, respectively. Each of the wheels preferably comprises a plurality of rotor magnets (e.g., in the form of rotor magnet disks) arranged within the inner surface of the outer periphery of the wheel, and a plurality of stators (e.g., in the form of stator disks) arranged at least partially, e.g., completely, within the vehicle body, preferably at the same or approximately the same height as the position of the wheel's axis of rotation. In this embodiment, the height refers to the distance from the highest point of the underlying storage system during use. The stator includes both a winding and a yoke, and the stator field winding follows the outer periphery of the wheel.

[0016] In another advantageous embodiment, at least part of the drive means, preferably the entire drive means, is arranged within the outer periphery of the wheel. For example, if four belts are applied to drive the vehicle of the present invention in the X and Y directions, a total of four motors may be placed in operative engagement with each of the four belts to achieve the desired rolling set-specific driving force. Similarly, if eight wheels are applied to drive the vehicle in the X and Y directions, a total of eight motors may be placed in operative engagement with each of the eight wheels to achieve the desired rolling set-specific driving force.

[0017] The present invention also relates to a storage system suitable for storing boxes, comprising a box storage structure with a plurality of storage rows, each storage row arranged to receive vertically stacked storage boxes, and a remotely operated carrier according to any of the above-mentioned embodiments.

[0018] In the following description, specific details are introduced to provide a thorough understanding of embodiments of the claimed transport and storage systems. However, those skilled in the art will understand that these embodiments may be practiced without one or more of the specific details, or with other components, systems, etc. In other instances, well-known structures or operations are not shown or described in detail to avoid obscuring aspects of the disclosed embodiments. [Brief explanation of the drawings]

[0019] [Figure 1] FIG. 1 is a perspective view of a prior art storage system including a grid and multiple remotely operated vehicles / robots. [Figure 2] 1 is a top perspective view of a remotely operated vehicle according to one embodiment of the present invention; [Figure 3] FIG. 3 is a perspective view from below of the carrier of FIG. 2. [Figure 4] 4 is a cross-sectional view of the vehicle of FIGS. 2 and 3 taken along one major orientation of the vehicle. FIG. [Figure 5] FIG. 1 is a perspective view of a storage system from above, according to one embodiment of the present invention, showing a carrier of the present invention positioned directly above five adjacent storage rows. [Figure 6] Figure 6A is a cross-sectional view of the storage system of Figure 5 showing carriers of the present invention on adjacent rows along one main orientation of the carriers, and Figure 6B is a cross-sectional view of the storage system of Figure 5 showing carriers of the present invention on adjacent rows along another main orientation of the carriers. [Figure 7] 1 is a perspective view of a rolling set forming part of a carrier according to one embodiment of the present invention; FIG. [Figure 8] Figures 8A and 8B are perspective views of a wheel that forms part of a transport device according to one embodiment of the present invention. [Figure 9] Figure 9A shows the rolling set of Figure 7 with one of the wheels removed, and is a cross-sectional view of the rolling set taken along one main orientation of the vehicle. Figure 9B shows the rolling set of Figure 7 with one of the wheels removed, and is a cross-sectional view of the rolling set taken along another main orientation of the vehicle. Figure 9C shows the rolling set of Figure 7 with one of the wheels removed, and is a perspective side view of a portion of the rolling set with the wheel removed. DETAILED DESCRIPTION OF THE INVENTION

[0020] All relative terms such as up, down, sideways, vertical, X-direction, Y-direction, Z-direction, etc. used to describe the vehicle of the present invention (hereinafter referred to as the robot) shall be interpreted using the prior art storage system referenced above (FIG. 1) as the reference system. For clarity, the X, Y, and Z directions are indicated in FIGS. 1-7 and 9 by a Cartesian coordinate system 100.

[0021] 2 and 3 provide perspective views from two different angles of the robot 1, which comprises a rectangular carrier body or framework 4 exhibiting a centrally located cavity therein, a top cover 72 covering the upper portion of the body 4, a first carrier rolling means 10 having four X wheels 101-104 for moving in the X direction on support rails 13 of an underlying box storage grid 15, and a second carrier rolling means 11 having four Y wheels for moving in the Y direction on support rails 13 of the underlying box storage grid 15, both of which are attached to the outer wall of the body 4. The size of the cavity within the robot 1 (FIG. 3) is adapted to accommodate at least the main portion, and most preferably the entire box, of the largest storage bin 2 intended to be picked up by the robot 1. The operation of picking up the storage bin 2 is performed by a lifting device 7, shown in a retracted position at the top end of the cavity in FIG. 3.

[0022] FIG. 4 shows a cross-sectional view of the robot 1 as viewed along the X direction. 5 and 6 show a portion of a storage system 3 in which robots 1 are positioned at various adjacent positions on top of a bin storage grid 15. In four of the five positions, robot 1 is positioned directly above a storage row of grid 15. As is most apparent in FIGS. 6A and 6B, which show the storage system 3 of FIG. 5 in cross-section along the Y and X directions, respectively, robot 1 is sized so that its maximum cross-sectional area along the XY plane is less than or equal to the cross-sectional area of the corresponding (underlying) storage row. Thus, two or more robots 1 can operate simultaneously on adjacent rows of grid 15, freeing up more space compared to prior art systems.

[0023] One side of the first carrier rolling means 10 is shown in a perspective side view in Figure 7. In this particular embodiment of the invention, the rolling means 10 comprises two wheels 101, 102 with outer rims / edges 9 located along the X direction near the corners of the carrier body 4. A cover plate 25, which forms part of the carrier body 4, is positioned between the two wheels 101, 102.

[0024] Further details of one of these wheels 101, 102 are provided in Figures 8A and 8B, showing the outer and inner surfaces, respectively. A rotary encoder 23 of the type shown is disposed within the inner radial surface of the outer rim 9. Other types of encoders may be used, such as magnetic encoders, linear encoders, voltage-based analog encoders, etc. The rotor 5 in Figure 8, shown as a set of permanent magnets 5, is disposed inside the periphery defined by the rotary encoder 23, i.e., closer to the axis of rotation of the wheel 101.

[0025] The corresponding stator 19 is shown in Figure 9 with electrical windings 19a wound around a yoke 19b, however, those skilled in the art will appreciate that the stator 19 and rotor 5 may (in other embodiments of the invention) consist of stator magnets and rotor yoke / windings, respectively.

[0026] Figures 9B and 9C also show an arrangement in which the means for measuring acceleration 24 are connected in signal communication with the stator 19 of each wheel 101, 102, for example by using a piezoelectric sensor. Figure 9A is a cross-sectional view of a portion of the first vehicle rolling means 10 taken along the X direction, showing the stator 19 surrounded by the outer rim 9.

[0027] All components and their interactions / configurations are valid for the second vehicle rolling means 11 as well. The positioning of the drive means 5, 19 close to or within the rolling means 10, 11 of the robot 1 contributes to freeing up space on the storage system during operation, thereby allowing the design of a more compact robot 1 compared to prior art robots.

[0028] All operations of the robot 1 are controlled by wireless communication means and a remote control unit, which includes one or more of controlling robot movement, controlling the carrier lift device 7, measuring robot position, measuring robot velocity, and measuring robot acceleration.

[0029] In the foregoing description, various aspects of the transport and storage system according to the present invention have been described with reference to exemplary embodiments. For purposes of explanation, the system and configurations have been described to provide a thorough understanding of the system and its operation. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiments, as well as other embodiments of the system, will be apparent to those skilled in the art to which the disclosed subject matter pertains and are deemed to be within the scope of the present invention. [Explanation of symbols]

[0030] 1 Remotely controlled vehicles / robots 2 storage box 3. Storage System 4. Carrier body / framework 5 Rotor / Permanent Magnet 7 Lifting device 9 Outer Rim / Outer perimeter of rolling means 10 First vehicle rolling means / first wheel set 11 Second vehicle rolling means / second wheel set 13 Support Rail 15 box storage lattice 19 Stator 19a winding 19b York 23 Rotary Encoder 24 Means for measuring acceleration / piezoelectric sensor 25 Cover plate 50 Box Lifting Device 60 shipping stations / ports 72 Top lid 100 Cartesian coordinate system 101 First X Wheel 101 Second X Wheel 102 Third X Wheel 103 4th X Wheel 111 First Y-Wheel 112 Second Y-Wheel 113 Third Y Wheel 114 Fourth Y-Wheel

Claims

1. A remotely operated carrier (1) for picking up a storage box (2) from an underlying storage system (3), comprising: a carrier lifting device (7) for lifting said storage box (2) from said underlying storage system (3); a first carrier rolling means (10) comprising a first set of rolling members (101-102) and a second set of rolling members (103-104) arranged on opposite side walls of the carrier body (4), which, in use, allows movement of said carrier (1) along a first direction (X) on said underlying storage system (3); a second carrier rolling means (11) comprising a first set of rolling members (111-112) and a second set of rolling members (113-114) arranged on opposite side walls of the carrier body (4), the second carrier rolling means (11) enabling, in use, movement of the carrier (1) on the underlying storage system (3) along a second direction (Y) perpendicular to the first direction (X); A transport device (1) in which each of the first and second rolling sets comprises at least two wheels (101-104, 111-114), first drive means (5, 19) located at least partially within said first carrier rolling means (10) for providing a rolling set-specific drive force to said carrier (1) in said first direction (X); second drive means (5, 19) located at least partially within said second carrier rolling means (11) for providing a rolling set-specific driving force to said carrier (1) in said second direction (Y); Furthermore, said at least one of said first driving means (5, 19) and said second driving means (5, 19) comprises a stator arranged at least partly in the same plane of rotation as said first and second carrier rolling means (10, 11) and at least partly within said carrier body (4); The vehicle (1) further comprises means (24) for measuring the acceleration of at least one of the vehicle rolling means (10, 11), the means (24) being in signal communication with the stator (19).

2. 2. A vehicle (1) according to claim 1, wherein at least one of the first and second drive means (5, 19) comprises an electric motor (5, 19) using permanent magnets (5).

3. 2. A vehicle (1) according to claim 1, wherein at least one of the first and second drive means (5, 19) comprises a brushless electric DC motor.

4. 4. A vehicle (1) according to any one of claims 1 to 3, wherein at least one of the first and second driving means (5, 19) comprises a rotor magnet (5) arranged on the inner surface of the outer rim (9) of the respective first or second vehicle rolling means (10, 11).

5. 5. A vehicle (1) according to any one of claims 1 to 4, comprising means (24) for measuring the electromotive force of at least one of the vehicle rolling means, the means (24) being in signal communication with one of the stator (19) and rotor (5) to enable rolling set-specific speed registration of the vehicle (1) during operation.

6. 6. A vehicle (1) according to any one of claims 1 to 5, wherein the means (24) for measuring acceleration comprises at least one of at least one piezoelectric sensor and an inductive sensor.

7. 7. A vehicle (1) according to any one of claims 1 to 6, comprising a rotary encoder (23) connected to at least one of the first and second vehicle rolling means (10, 11) to enable angular position feedback during operation.

8. 8. A vehicle (1) according to claim 7, wherein the rotary encoder (23) is of the type of absolute rotary encoder, the absolute rotary encoder being of the type of optical encoder.

9. 9. A vehicle (1) according to claim 7 or 8, wherein the rotary encoder (23) is a rotary encoder disc arranged within the outer rim (9) of at least one of the first and second vehicle rolling means (10, 11).

10. 10. The vehicle (1) according to any one of claims 1 to 9, further comprising motor control electronics arranged in a volume between two of the wheels of each rolling set (101-104, 111-114), the motor control electronics being configured to supply power to the first and second vehicle rolling means (10, 11).

11. The first carrier rolling means (10) comprises four X wheels (101-104) having a rotation direction in the first direction; The second carrier rolling means (11) comprises four Y wheels (111-114) having a rotation direction in the second direction; each of said X wheels and each of said Y wheels are drivingly connected to said first drive means (5, 19) and said second drive means (5, 19), respectively; A carrier (1) according to any one of claims 1 to 10.

12. 12. The vehicle (1) of claim 11, wherein each of the wheels (101-104, 111-114) comprises a plurality of rotor magnets (5) disposed within an inner surface of the outer periphery (9) of the wheel, and a plurality of stator field windings (19a) disposed at least partially within the vehicle body (4).

13. 13. A vehicle (1) according to claim 12, wherein the stator field winding (19a) is wound around a yoke, the stator field winding (19a) following the outer periphery (9) of the wheels (101-104, 111-114).

14. A vehicle (1) according to any one of claims 11 to 13, wherein for each wheel (101-104, 111-114), at least a part of the first and second drive means (5, 19) is arranged within the outer periphery (9) of said wheel.

15. A storage system (3) for storing boxes (2), comprising: a box storage structure (15) having a plurality of storage rows (8, 8a, 8b) arranged to accommodate vertically stacked storage boxes (2); A carrier (1) according to any one of claims 1 to 14, placed on the box storage structure (15); A storage system (3).

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