Single-piece hinge and related methods and uses

Abstract

A single-piece hinge, method of manufacturing, and load handling device are provided, the single-piece hinge comprising a first part and a second part and a flexure arrangement connecting a first end of the first part to a first end of the second part, the single-piece hinge being movable in rotation about a pivot point at the first end of the first part and movable between a first position and a second position, in which the rotation is limited by a first support area and in which the rotation is limited by a second support area.

Description

[Technical Field]

[0001] The present invention relates to single-piece hinges. More particularly, but not exclusively, the present invention relates to single-piece flexure hinge mechanisms and methods of manufacture. [Background technology]

[0002] A robotic load handling device is described in UK Patent Application No. GB2520104A (Ocado Innovation Limited). Such load handling devices are controllably moved on a track system that forms a grid above a stack of receptacles or containers. A given load handling device lifts a target container from the top of the stack, the target container containing inventory items needed to fulfill a customer order. The load handling device includes a first set of wheels and a second set of wheels for engaging with x-direction and y-direction tracks, respectively. To move in the x-direction, the x-direction wheels are engaged with the tracks, while the y-direction wheels are elevated. Similarly, to move in the y-direction, the y-direction wheels are engaged with the tracks, while the x-direction wheels are elevated. The transition between x-direction and y-direction movement is controlled by a turning mechanism. It is essential that the turning mechanism be sturdy, reliable, capable of supporting the weight of the load handling device and the target container, and able to withstand repeated use.

[0003] It is against this background that the present invention was conceived. Summary of the Invention

[0004] Single-piece hinge A single-piece hinge is provided, the single-piece hinge comprising a first part and a second part, and a flexure arrangement connecting a first end of the first part to a first end of the second part, the single-piece hinge being movable in rotation about a pivot point at the first end of the first part and movable between a first position and a second position, wherein in the first position the rotation is limited by a first support area and in the second position the rotation is limited by a second support area.

[0005] The first and second portions can be compared to the leaves of a typical hinge.

[0006] A flexure is a flexible element or combination of elements designed to accommodate a specific degree of freedom. Typically, a flexure comprises a thin bar, sheet, or cutout of material that can bend more easily than the surrounding material. A specific design allows for complex motion profiles with specific degrees of freedom and travel distances.

[0007] The flexure arrangement may be considered to be the pivot or tip of the hinge, although the "axis" may not be fixed in space relative to the first and second portions.

[0008] In some constructs, the single-piece hinge may have a substantially cylindrical "leg" shape to support weight and movement. If the single-piece hinge is considered to be the leg, the first portion may be the "shin" (between the knee and the ankle), where the front of the shin is the "shin" and ends at the "heel," the second portion may be the "foot," and the flexure construct may be the "ankle."

[0009] The single-piece hinge is configured to move between two positions. In the first position, the leg or heel rests backward on the ankle or first support area, and in the second position, the leg rests forward with the shin resting on the top of the foot or second support area. Loads transmitted by the hinge pass through the first support area (the heel) in the first position and through the second support area (the top of the foot, the shin) in the second position. In this manner, forces transmitted by the leg are supported by the first and second support areas in both the first and second positions. The flexure structure transmits minimal or substantially no load compared to the support areas, while the first and second portions transmit substantially all of the load transmitted through the single-piece hinge.

[0010] Thus, the support region may enable the first and second portions to be structural elements. The support region may enable the single-piece hinge to move between the first and second positions with minimal force because only minimal force is transmitted by the flexure structure, and therefore there is substantially no force to overcome to move the flexure structure between positions.

[0011] It should be appreciated that because the hinge is a single piece, the number of parts required may be reduced.

[0012] Typically, a hinge requires two leaves extending laterally from a knuckle(s). The knuckles extending from each leaf are arranged alternately and interlock with a pin that passes through them. This typically results in a hinge having multiple parts, e.g., eight parts with separate leaves, pins, and multiple bearings. Reducing the number of parts to one can mean reduced assembly time. Furthermore, there is no need for good tolerances between parts, nor does lubrication need to be applied between parts. Therefore, the costs associated with assembling a single-part hinge into a more complex configuration can be reduced.

[0013] Furthermore, it should be recognized that a reduction in the number of parts may translate into a reduction in the overall weight required for the single-part hinge. For example, it may be possible to topology optimize the single-part hinge.

[0014] The contact portion between the first and second portions of the first support region may have a complementary shape.

[0015] In other words, in the first support region, the first end of the first portion is mated with the first end of the second portion, and they meet or abut congruently to fit or fasten together. In some cases, the pieces may be manufactured together with perforations between them to ensure a good shape match. The perforations may then be broken when ready for use.

[0016] The junction between the first and second sections in the first support region can be at least partially castellated. The castellation can help reduce any lateral or torsional forces on the flexure arrangement. Additionally, the castellation can help ensure that the leg is properly seated at the ankle when moving to the first position.

[0017] As mentioned above, the load is carried substantially through the first and second support regions rather than the flexure arrangement itself. Having complementary shapes between where the first and second portions meet can mean that the force is transferred more directly and can mean that the force is distributed over an area.

[0018] The shape of the second portion guides the first portion into the first position.

[0019] In this way, it can be ensured that the first and second portions come together substantially accurately and as intended when the single-piece hinge moves to the first position. Such guidance provided by the shape can further reduce the risk of lateral or torsional forces, thereby providing at least some protection to the flexure arrangement.

[0020] Another advantage may be that the guides ensure smooth and uniform operation of the single-piece hinge as it moves between positions.

[0021] Additionally, at least a portion of the joint or interface between the first and second portions may be curved, which again may ensure smooth and uniform operation of the single-piece hinge as it moves between positions.

[0022] The single-piece hinge may be at least partially supported by the first support region at substantially all positions between the first and second positions, and in this manner, the hinge is substantially supported throughout its use.

[0023] The first support area of the second portion has a shark tooth shape.

[0024] On both the leading and trailing edges, shark tooth shapes are curved in the same direction. The leading and trailing edges meet at the tip.

[0025] In the first position, the tips of the "teeth" protrude from the first end of the second part into the recesses in the first end of the first part. In the second position, the end of the first part swings forward and the tips of the "teeth" are not fully seated in the recesses but remain in contact with them. Thus, in the second position, the load can be distributed between the first and second support regions, where there is partial contact between the first and second parts at the first support region.

[0026] The contact portion between the first and second portions of the second support region has a complementary shape.

[0027] Similar to the heel or first support area, the bottom of the shin is mated with the top of the foot and may meet or abut in unison.

[0028] In some constructions, the bottom of the shin and the top of the foot can be substantially flat or planar. Because the second support area can be distal to the flexure construction, there can be substantially less need to protect against lateral or torsional forces on the flexure construction. Having a substantially flat contact area can mean that forces are more evenly distributed across the surface, it is easier to manufacture, and tolerance issues are less likely to occur.

[0029] The flexure arrangement is at least partially bounded on a lateral side by a first support region.

[0030] It will be appreciated that the flexure arrangement may be delicate or weak compared to the first and second portions because it is required to bend according to a specially designed degree of freedom.

[0031] The ends of the first portion may extend downward toward the second portion on either side of the flexure structure, thereby bounding or flanking the flexure structure. The first portion may intersect with the second portion. In this manner, advantageously, forces transmitted by the first portion may be transmitted directly to the second portion, effectively bypassing the flexure structure in the first support region.

[0032] The flexure structure is at least partially nested within the first end of the first portion. The flexure structure is at least partially nested within the first end of the second portion.

[0033] In other words, the flexure structure may be housed or surrounded between the first and second parts. Advantageously, the flexure structure may be substantially surrounded by the first part on four sides and the second part on two sides. Thus, the flexure structure may be substantially protected by the first and second parts.

[0034] It should be appreciated that the first support region comprises a portion of the first portion and the second portion where the first portion and the second portion intersect.

[0035] The first portion includes a rocker at a first end of the first portion and the second portion includes a socket, where the rocker is located within the socket.

[0036] A rocker and socket arrangement between the first and second portions may ensure that the end of the first portion "self-locates" into the second portion. In other words, the first portion may comprise a ball end and the second portion may comprise a cup. Advantageously, there may be smooth movement between the first and second positions. Advantageously, friction between the rocker and socket may be low.

[0037] The flexure arrangement comprises one or more strip(s) of material extending between the first portion and the second portion.

[0038] As described above, a flexure typically comprises a thin bar, sheet, or cutout of material that can bend more easily than the surrounding material. The flexure configuration may comprise one or more flexure components. The flexure components may be strips or ribbons of material. The strip(s) of material may have a relatively long longitudinal or length dimension, a short depth or thickness dimension, and an intermediate width dimension to allow bending in the front-to-rear direction. The flexures may be blade-type flexures. A first end of each strip may be attached to the first portion, and a distal end of each strip may be attached to the second portion.

[0039] At least one strip extends in a first direction and at least one strip extends in a second direction substantially opposite the first direction.

[0040] The flexure arrangement may comprise two or more strips: one or more first strip(s) extending in a forward direction, i.e., in the direction of movement from the hinge first position to the hinge second position, and one or more second strip(s) extending in a reverse or rearward direction, i.e., in the direction of movement from the hinge second position to the hinge first position.

[0041] In this manner, the two or more strips may form an "X." The midpoint of the "X" may be the pivot point of the single-piece hinge. The midpoint of the flexure structure may be configured to coincide with one or more edges of the bounding first support region. In this manner, the flexure structure is substantially supported by the first support region throughout its movement between the first and second positions of the single-piece hinge.

[0042] By having flexure strips that extend in first and second directions, the movement of the single piece hinge can be controlled in both directions of movement, ie, forward and reverse.

[0043] The flexure structure comprises a single strip extending in a first direction and two strips extending in a second direction, the single strip extending in the first direction having a width equal to the combined width of the two strips extending in the second direction.

[0044] It should be appreciated that by adjusting the width of the strip(s) in the first direction relative to the strip(s) in the second direction, it is possible to correspondingly adjust the force required to move the single-piece hinge in the first or forward direction and the second or reverse direction. Thus, it is possible to design a single-piece hinge that requires more force to move in one direction than in the reverse direction. This can bias the hinge toward one direction. Alternatively, it should be appreciated that if the overall width of the strips in the first direction matches the overall width of the strips in the second direction, the single-piece hinge will be substantially balanced, requiring approximately equal force to move in either direction.

[0045] Each strip of flexure structure is separated from other features by gaps on each side along its length.

[0046] In this way, each strip may be able to move freely without being impeded by the other parts of the single-piece hinge. It should be appreciated that as a result of the gap between the strip(s) and the other components, there is little or substantially no friction moving the single-piece hinge between the first position and the second position, and vice versa. As a result, less force is required to move the single-piece hinge between positions. If the hinge is operated by a motor, a smaller motor may be used, thereby representing capital and energy cost savings.

[0047] This freedom of movement can be in contrast to conventional or typical hinges, bearings, or slides, which often exhibit positioning hysteresis due to backlash and / or friction. Hence, a single-piece hinge can be movable to position with high predictability.

[0048] The first portion, the second portion, and the flexure structure are formed from a single piece of material.

[0049] It should be appreciated that a single-piece hinge is made from a single, continuous piece of material. Typically, the material will be selected to exhibit appropriate elasticity, flexibility versus stiffness, resilience, and fatigue characteristics. It should be appreciated that some material properties depend on the mode of manufacture. It should be appreciated that some material properties are anisotropic. Suitable materials may be plastic, polymer plastic, thermoset plastic, thermoplastic, metal, aluminum, aluminum alloy, iron, iron alloy, steel, steel alloy, magnesium, magnesium alloy, titanium, titanium alloy, zinc, zinc alloy, fiber reinforced composite, carbon fiber, graphite fiber, glass fiber, natural fiber, plant fiber, plastic fiber, paper, cardboard, rubber, epoxy, or nylon.

[0050] The single-piece mechanism is 3D printed or constructed through additive manufacturing.

[0051] By using additive printing or 3D printing, it is often possible to manufacture more complex shapes. It should be recognized that additive processes can result in anisotropic material properties. With some additive manufacturing methods, it is possible to use more than one material and grade the transition between materials. These methods are anticipated.

[0052] The first portion further comprises a window for removing excess material.

[0053] It should be appreciated that some additive manufacturing methods use sintering of powder materials. Excess powder that needs to be removed may be left on the product after the sintering process is complete. It should be appreciated that excess powder located between sections of a single-piece hinge may be difficult to remove.

[0054] The window may be located on the back of the heel. The window may have a letterbox shaped profile. More than one window may be used.

[0055] It should be appreciated that the window may be advantageously used to aid in the removal of excess material.

[0056] Additionally, it should be appreciated that the window may be used to inspect the internal components of a single piece hinge.

[0057] [use] A single-piece mechanism can be used as a linkage set to convert horizontal force into vertical motion.

[0058] The linkage set may include a direction change mechanism.

[0059] A second single-piece hinge is formed at a second end of the first portion distal from the first end of the first portion to form a double single-piece hinge linkage.

[0060] A load handling device for lifting and moving storage containers stacked in a grid framework structure may comprise a first set of parallel rails or tracks and a second set of parallel rails or tracks extending substantially perpendicular to the first set of rails or tracks in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces, the grid being supported by a set of uprights to form a plurality of vertical storage locations beneath the grid such that containers are stacked vertically between the set of uprights through the plurality of grid spaces and guided by the set of uprights, the load handling device comprising: a body mounted on a first set of wheels configured to engage with the first set of parallel tracks and a second set of wheels configured to engage with the second set of parallel tracks; and a diverting assembly configured to raise or lower the first set of wheels and / or lower or raise the second set of wheels relative to the body to engage and disengage the wheels from the parallel tracks, the diverting assembly comprising a linkage set comprising a series of single-piece hinges disposed between a traveler and a fixed brace, the traveler being configured to move under an applied force to allow the wheels to be raised or lowered.

[0061] These are some examples of the use of single piece hinges.

[0062] It should be appreciated that a single-piece hinge can be used as part of several different linkages, and that more than one single-piece hinge can be incorporated into a piece to create complex mechanisms.

[0063] [Manufacturing] A method of manufacturing a single-piece hinge is provided, the method comprising printing a digital model of the single-piece hinge using an additive manufacturing device, removing the printed single-piece hinge from the additive manufacturing device, and removing excess material from the single-piece hinge.

[0064] As mentioned above, the single-piece hinge can be manufactured by 3D printing or additive manufacturing. In particular, selective laser sintering (SLS) 3D printing can be used. The SLS method can be particularly advantageous for printing the disclosed single-piece hinge because during the printing process, the part being built is supported by unsintered powder material throughout the process. This allows geometries that are not possible using some other techniques to be built. For example, SLS techniques can be used to fabricate "nested" elements. Alternatively, multi-jet fusion (MJF) 3D printing is another powder-based technique in which an injection array applies flux and detailing agents, which are then combined by heating to create a solid layer. It should be recognized that any suitable additive manufacturing technique or apparatus can be used, and the present disclosure is not limited to the techniques described herein.

[0065] It should be appreciated that additive manufacturing methods typically fabricate or build pieces according to "sliced" layers. It should be appreciated that the direction of the "slicing" can affect the material behavior of the finished piece. Therefore, the direction of fabrication can be specified to ensure intended properties for the piece result at the end of the process. This can be particularly important for the single-piece hinges disclosed herein, as the flexure structure is required to flex in a specific direction.

[0066] It should be appreciated that for the single-piece hinges disclosed herein, particularly when powder techniques are used, it may be necessary to remove excess material after fabrication in the build chamber. Removal of excess material may be performed manually or by an automated or semi-automated process. Other post-processing steps may optionally be performed.

[0067] As mentioned above, a window or letterbox feature on the heel of the single-piece hinge can be used to aid in the removal of excess powder. The window can also be used to inspect the internal components, i.e., the flexure arrangement of the hinge, to ensure that the components are properly aligned.

[0068] In an automated cleaning process, the printed part may be placed in a tumbling machine to shake off excess material from the printed part. It should be recognized that the part may be subjected to forces that are not present during normal use of the part. In the case of a single-part hinge, castellation features may help protect more delicate features, such as flexure structures, during the cleaning process.

[0069] The single piece hinge may then be ready to be assembled into a more complex mechanism.

[0070] As described above, the interface between the first and second parts can have complementary shapes. Using additive manufacturing techniques, a single-piece hinge can be designed with a first and second part joined with a thin strip of material between the parts. After manufacturing, the interface can be split to allow movement between the first and second parts. In this way, the interface between the first and second parts can be complementary despite any distortion or change in shape resulting from the manufacturing process. In other words, regardless of manufacturing tolerances, the first and second parts will have substantially complementary shapes. Advantageously, this can result in fewer rejected printed parts.

[0071] According to the examples discussed herein, a single piece hinge can be assembled into a linkage set for a turning mechanism.

[0072] A set or series of single-piece hinges may be attached to the upper brace by slotting each single-piece hinge onto a corresponding shaft extending from the upper brace. Similarly, each single-piece hinge may be slotted onto a corresponding shaft extending from the lower brace. A cap plate may then be attached to secure the pieces together. In this manner, the linkage set may be quickly and easily assembled and may have fewer parts and a simple assembly process. Four linkage sets may be assembled as a diversion assembly, one on each side of the load handling device. It should be recognized that the reduction in assembly time for the diversion assembly is a multiple of the reduction in assembly time for each linkage set. Therefore, single-piece hinges may enable significant savings.

[0073] Other variations and advantages will become apparent from the following description.

[0074] These and other aspects of the present invention will now be described, by way of example only, with reference to the accompanying drawings. [Brief explanation of the drawings]

[0075] [Figure 1] 1 illustrates a storage structure. [Figure 2] 1 illustrates a track structure. [Figure 3] 2 illustrates a robotic load handling device on top of the storage structure illustrated in FIG. 1. [Figure 4] 1 illustrates a robotic load handling device or bot. [Figure 5] 1 illustrates a robotic load handling device or bot. [Figure 6] 6 illustrates a load handling device and turning assembly, where in FIG. 6a the load handling device is parked, in FIG. 6b the x-direction wheels are raised while the y-direction wheels are lowered for movement in the y-direction, and in FIG. 6c the y-direction wheels are raised while the x-direction wheels are lowered for movement in the x-direction. [Figure 7] 7 illustrates a linkage set for a turning assembly, with the linkage set in a parked position in FIG. 7a, the wheel chassis raised for lateral movement in FIG. 7b, and the wheel chassis lowered for parallel movement in FIG. 7c. [Figure 8] 8 illustrates a single-piece hinge with a flexure structure, where FIG. 8a is an isometric view of a cross section through the flexure structure, FIG. 8b is an XY plane view through the flexure structure, FIG. 8c is a view of the single-piece hinge in the ZY plane, and FIG. 8d is a view of the hinge in the ZX plane. [Figure 9] 9A and 9B illustrate another single-piece hinge with a flexure arrangement, where FIG. 9A is a view in the ZY plane and FIG. 9B is a view in the ZX plane. [Figure 10] 10A illustrates another single-piece hinge with a flexure arrangement, where FIG. 10A is a view of the hinge in the ZX plane and FIG. 10B is a cross-sectional view. [Figure 11] 11 illustrates the single-piece hinge of FIG. 10, where FIG. 11a is a view of the hinge in the ZY plane, and FIGS. 11b-d are detailed cross-sectional views, where FIG. 11b is in the raised position, FIG. 11c is in the parked position, and FIG. 11d is in the lowered position. [Figure 12] 12a is a schematic diagram of a flexure arrangement, where FIG. 12a is at rest and FIG. 12b is flexure. [Figure 13] 13 illustrates the single-piece hinge of FIGS. 10 and 11, where FIG. 13a is a view of the hinge in the ZX plane, FIG. 13b is a cross-sectional isometric view, and FIG. 13c is a cross-sectional YX view. [Figure 14] 14 illustrates details of the single-piece hinge of FIGS. 10, 11, and 13, where FIG. 14a is an isometric view and FIG. 14b is a ZY plane view. [Figure 15a-e] 15 illustrates a construction using two single-piece hinges, where FIG. 15a is a ZX front view, FIG. 15b is a ZY view, FIG. 15c is a ZX rear view, FIG. 15d is an XY top view, and FIG. 15e is a ZX cross-sectional view. [Figure 15f-i]An arrangement using two single-piece hinges is illustrated, where FIG. 15f is an isometric front view, FIG. 15g is an isometric back view, FIG. 15h is an XY bottom view, and FIG. 15i is a ZY cross-sectional view. [Figure 16] Illustrates a diagram of the manufacturing and assembly process. DETAILED DESCRIPTION OF THE INVENTION

[0076] In the figures, like features are designated by like reference numerals where appropriate.

[0077] The following embodiments represent preferred examples of how the present invention may be implemented, but they are not necessarily the only examples of how this may be achieved. These examples are described in sufficient detail to enable one skilled in the art to practice the present invention. Other examples may be utilized, and structural changes may be made, without departing from the scope of the present invention, as defined in the appended claims. Furthermore, directional references and any other terms that have an implicit direction are provided as examples to aid the reader's understanding of the specific examples described herein. They should not be read as requirements or limitations on the specific position, orientation, or use of the present invention, unless specifically recited in the appended claims. Similarly, connection references (e.g., attached, coupled, connected, joined, secured, etc.) should be interpreted broadly and may include intermediate members between connections of elements and relative movement between the elements. Thus, connection references do not necessarily imply that two elements are directly connected and in a fixed relationship to each other, unless specifically recited in the appended claims. Similarly, phrases such as "movement in the n-direction," where n is one of x, y, and z, and any equivalent phrases, are intended to mean movement substantially along or parallel to the n-axis in either direction (i.e., toward the positive end of the n-axis or toward the negative end of the n-axis).

[0078] 1 illustrates a storage structure 1 comprising upright members 3 and horizontal members 5, 7 supported by upright members 3. Horizontal members 7 extend parallel to each other and to an illustrative x-axis, while horizontal members 5 extend transversely to horizontal members 7, parallel to each other and to an illustrative y-axis. Upright members 3 extend parallel to each other and to an illustrative z-axis. Horizontal members 5, 7 form a grid pattern defining a plurality of grid cells. In the illustrated example, containers 9 are arranged in stacks 11 beneath the grid cells defined by the grid pattern, with one stack 11 of containers 9 per grid cell.

[0079] FIG. 2 shows a large-scale plan view of a section of a track structure 13 located on top of the horizontal members 5, 7 and forming part of the storage structure 1 illustrated in FIG. 1. The track structure 13 may be provided by the horizontal members 5, 7 themselves (e.g., formed in or on the surface of the horizontal members 5, 7) or by one or more additional components mounted on top of the horizontal members 5, 7. The illustrated track structure 13 includes x-direction tracks 17 and y-direction tracks 19. In this case, a first set of tracks 17 extends in the x-direction, and a second set of tracks 19 extends in the y-direction transverse to the first set of tracks 17. The tracks 17, 19 define apertures 15 at the centers of grid cells. The apertures 15 are sized to allow containers 9 located directly below the grid cells to be lifted and lowered through the apertures 15. The first set of tracks 17 are provided in pairs separated by ridges 21, and the second set of tracks 19 are provided in pairs separated by ridges 23. Other arrangements of the track structure may also be possible.

[0080] Figure 3 shows multiple robotic load handling devices 31 moving on top of the storage structure 1 illustrated in Figure 1. Each load handling device 31, which may also be referred to as a robot 31 or bot 31, is provided with a turning assembly (not shown) and a set of wheels for engaging with a corresponding x-direction track 17 or y-direction track 19 to enable the bot 31 to move across the track structure 13 and reach a particular grid cell. As noted, the sets of tracks 17, 19 are separated by ridges 21, 23 that allow a pair of bots 31 to occupy adjacent grid cells or pass each other without colliding.

[0081] 4, the bot 31 comprises a body 33 with one or more components mounted therein or thereon that enable the bot 31 to perform its intended functions. These functions may include moving across the storage structure 1 on the track structure 13 and lowering or raising containers 9 into or from the stacks 11 so that the bot 31 can place or retrieve containers 9 from specific locations defined by the grid pattern.

[0082] To perform the former function, the bot 31 includes a first set 35 and a second set 37 of wheels, which are mounted on the body 33 and enable the bot 31 to move in the x and y directions along the tracks 17 and 19, respectively. In particular, two wheels 35 are provided on the shorter side of the bot 31 visible in FIG. 4 , and two more wheels 35 are provided on the opposite shorter side 36 of the bot 31. The wheels 35 are rotatably mounted on the body 33 and configured to engage with the track 17 to enable the bot 31 to move along the track 17. Similarly, two wheels 37 are provided on the longer side of the bot 31 visible in FIG. 4 , and two more wheels 37 are provided on the opposite longer side 38 of the bot 31. The wheels 37 engage with the track 19 and are rotatably mounted on the body 33 of the bot 31 to enable the bot 31 to move along the track 19.

[0083] To enable the bot 31 to move on different wheels 35, 37 in first and second directions, the bot 31 includes a wheel positioning mechanism for selectively engaging either the first set of wheels 35 with the first set of tracks 17 or the second set of wheels 37 with the second set of tracks 19. The wheel positioning mechanism is configured to raise and lower the first set of wheels 35 and / or the second set of wheels 37 relative to the body 33, thereby enabling the load handling device 31 to selectively move in either the first direction or the second direction across the tracks 17, 19 of the storage structure 1.

[0084] The wheel positioning mechanism may include one or more linear actuators, rotary components, or other means for raising and lowering at least one set of wheels 35, 37 relative to the body 33 of the bot 31 to move the at least one set of wheels 35, 37 away from and into contact with the tracks 17, 19. In some examples, only one set of wheels is configured to be raised and lowered, such that the act of lowering one set of wheels may effectively lift the other set of wheels away from the corresponding tracks, while the act of raising one set of wheels may effectively lower the other set of wheels into contact with the corresponding tracks. In other examples, both sets of wheels may be raised and lowered, advantageously meaning that the body 33 of the bot 31 remains at substantially the same height, thus eliminating the need for the weight of the body 33 and components mounted thereon to be lifted and lowered by the wheel positioning mechanism.

[0085] To facilitate this latter function, the bot 31 further comprises container lifting means, generally designated 39, configured to raise a container 9 from the stack 11 into a container-receiving space or cavity of the bot 31 and lower a container 9 from the container-receiving space onto the stack 11. The illustrated container lifting means 39 comprises four tapes or reels 41 connected at their lower ends to a container engaging assembly 43. The tapes 41 may be wound up or unwound as required to raise or lower the container engaging assembly 43. One or more motors or other means may be provided to effect or control the winding or unwinding of the tapes 41.

[0086] As can be seen in FIG. 5 , the body 33 of the illustrated bot 31 has an upper portion 45 and a lower portion 47. The upper portion 45 is configured to accommodate one or more operating components (not shown). The lower portion 47 is positioned directly below the upper portion 45 and includes a container-receiving space or cavity for accommodating at least a portion of a container 9 elevated by the container lifting means 39. The container-receiving space is sized so that enough containers 9 can fit inside the cavity to allow the bot 31 to travel across the topmost track structure 13 of the storage structure 1 without the underside of the containers 9 getting caught on the track structure 13 or another portion of the storage structure 1. When the bot 31 reaches its intended destination, the container lifting means 39 controls the tape 41 to lower the container-engaging assembly 43 and corresponding container 9 from the cavity in the lower portion 47 to an intended location. The intended location may be the stack 11 of containers 9 or the exit point of the storage structure 1 (or the entry point of the storage structure 1 if the bot 31 travels to collect containers 9 for storage therein). In the illustrated example, the upper portion 45 and the lower portion 47 are separated by a physical partition, but in other embodiments, the upper portion 45 and the lower portion 47 may not be physically separated by a particular component or portion of the body 33 of the bot 31.

[0087] In some embodiments, the container receiving space of the bot 31 may not be within the body 33 of the bot 31. For example, in some embodiments, the container receiving space may be adjacent to the body 33 of the bot 31 (e.g., in a cantilever configuration in which the weight of the body 33 of the bot 31 balances the weight of the container to be lifted). In such embodiments, the frame or arm of the container lifting means 39 may protrude horizontally from the body 33 of the bot 31, and the tape / reel 41 may be disposed at respective locations on the protruding frame and configured to be raised and lowered from those locations to raise and lower the container into the container receiving space adjacent the body 33. The height at which the frame is mounted on and protrudes from the body 33 of the bot 31 may be selected to provide a desired effect. For example, it may be preferable for the frame to protrude at a high level above the body 33 of the bot 31 to allow a relatively larger container or multiple containers to be lifted into the container receiving space directly below the frame. Alternatively, the frame may be arranged to protrude lower below the body 33 (but still high enough to accommodate at least one container between the frame and the track structure 13) to keep the center of mass of the bot 31 lower when the bot 31 is loaded with containers.

[0088] In the embodiment shown, the container engaging assembly 43 comprises a gripper plate 49 attached to the lower end of the tape 41 and one or more gripper assemblies (not shown) mounted thereon for latching to the container 9. For example, the gripper assemblies, which may be provided at the corners of the gripper plate 49 near the tape 41, are aligned with and positioned to interact with recesses or openings in the container 9 when actuated to latch to the container 9.

[0089] FIG. 6 illustrates a perspective view of a load handling device 102 having a turning assembly 110 in three positions: parked, y-travel, and x-travel.

[0090] In Figure 6a, both the x-direction wheel chassis 116 and the y-direction wheel chassis 118 are down, so that when the load handling device is positioned on the grid structure as described above, all wheels will be engaged with the track. In Figure 6b, to move in the y-direction, the x-direction wheel chassis 116 is raised while the y-direction wheel chassis 118 is lowered, and in Figure 6c, to move in the x-direction, the y-direction wheel chassis 118 is raised while the x-direction wheel chassis 116 is lowered. Each of the wheel chassis 116, 118 is moved vertically by connection to the turning assembly 110, as described in more detail below. The wheel chassis 116, 118 are at the same vertical or z-level in the parked position.

[0091] The turning assembly includes a linkage set on each side of the load handling device 102. In Figure 6, a linkage set is shown on the visible x-direction side, with a similar linkage set located on the opposite x-direction side (not shown). Similarly, a linkage set is shown on the visible y-direction side, with a similar linkage set located on the opposite y-direction side (not shown). Each linkage set is connected to a corresponding wheel chassis 116, 118 for a particular side.

[0092] 7 illustrates a linkage set 120 for the diverting assembly 110. The linkage set 120 comprises a series of five similar hinges 121 pivotally connected between an upper brace or traveler 122 and a lower brace 123. On a load handling device, the lower brace 123 would be fixedly attached to the wheel chassis. If each hinge 121 were considered to be part of a leg, the hinge 121 would be attached to the upper brace 122 at the knee and to the lower brace 123 at the toe, with the hinge rotating about the ankle. Thus, each hinge 121 extends between the traveler 122 and the lower brace 123.

[0093] In Figure 7, dotted lines are drawn to provide a reference between Figures 7a, 7b and 7c.

[0094] In Figure 7a, linkage set 120 is in a parked position, in which the lower part or foot of the hinge is substantially horizontal and the upper part or shin of the hinge is tilted slightly forward in the positive x-direction, as shown in the drawing.

[0095] Compared to FIG. 7a, in FIG. 7b, the upper brace 122 is moved in the positive x-direction. This requires the linkage set to rotate substantially clockwise. In the position shown in FIG. 7b, the foot is rotated clockwise about the toe so that the foot is raised at the heel or hinge end distal to the toe. The shin is rotated counterclockwise about the ankle so that the shin returns to the heel and the foot and shin are substantially vertical, and the knee is rotated clockwise. As a result, the distance in the z-direction between the upper brace 122 and the lower brace 123 is reduced. This will raise the wheel chassis when the lower brace 123 is attached to the wheel chassis.

[0096] Compared to FIG. 7a, in FIG. 7c, the upper brace 122 is moved in the negative x-direction. This requires the linkage set to rotate substantially counterclockwise. In the position shown in FIG. 7c, the foot remains substantially horizontal. The shin is rotated counterclockwise about the ankle so that the shin is substantially vertical and returns to the heel and foot. From this, the foot and shin are substantially vertical. The knee is rotated counterclockwise. As a result of the positioning, the distance in the z-direction between the upper brace 122 and the lower brace 123 increases. Thereby, when the lower brace 123 is attached to the wheel chassis, the wheel chassis will be lowered to engage the wheels with the tracks for movement in the x-direction.

[0097] Clockwise and counterclockwise rotation about the ankle is restricted as described below.

[0098] From this, the linkage set converts horizontal motion into vertical motion and provides three vertical positions: park or neutral, up, and down.

[0099] It should be appreciated that the relative lengths of the shank and foot of the hinge 121 can be adjusted to achieve the designed vertical movement.

[0100] Figure 8 illustrates a single-piece hinge 130 with a flexure structure. Figure 8c is a view of the single-piece hinge 130 in the ZY plane, and Figure 8d is a view of the single-piece hinge 130 in the ZX plane. As illustrated, the single-piece hinge 130 is in a lowered position, with the foot 131 substantially horizontal and the shin 132 substantially vertical and perpendicular to the foot 131. A flexure structure 133 connects the shin 132 and the foot 131 at the ankle.

[0101] As can be seen in Figure 8d, at the heel, the shin 132 is shaped with supports 134 extending to each side of the shin 132. A flexure arrangement 133 can be seen between the two branches of the support region.

[0102] Figure 8a is an isometric view of a cross section cut through flexure structure 133 of foot 131, and Figure 8b is an XY plan view cut through flexure structure 133 of foot 131. As can be seen, for this single piece hinge 130, flexure structure 133 is a single strip of material configured to flex forward or clockwise towards toe 135 and backward or counterclockwise towards the heel.

[0103] The sides of the shin end 136 are rounded and extend downward toward the foot 131 on either side of the flexure arrangement 133, resting in a cup-shaped recess 137 in the foot 131 and allowing the shin 132 to rock on the foot 131 as controlled by the flexure arrangement 133. The flexure arrangement is bounded by the shin end 136, the support area 134, and the front portion of the foot 131.

[0104] Rotation of the single piece hinge 130 is limited in the counterclockwise direction by the bearing area 134 and in the clockwise direction by the shin or front part 138 of the shin that rests on top of the foot 131 .

[0105] Loads transmitted vertically through the single piece hinge 130 are directed through the shin 132 and the top of the support 134 or foot 131 .

[0106] FIG. 9 illustrates another single-piece hinge 140. FIG. 9a is a view of the single-piece hinge 140 in the ZY plane, and FIG. 9b is a view of the single-piece hinge 140 in the ZX plane. The single-piece hinge 140 is generally similar to the single-piece hinge 130 discussed in connection with FIG. 8, except for the differences described here. A support 141 extends from the foot 142 and is angled counterclockwise along the heel edge, while a shin end rocker 143 has a complementary shape. The socket or cup 146 in the foot 142 and the support 141 allow for a shorter angle of rotation about the ankle. As can be seen through a window in the heel, a flexure structure 144 has three strips of material connecting the shin 145 and the foot 142.

[0107] A third single-piece hinge 150 is illustrated in FIGS.

[0108] Single piece hinge 150 has shin 151 and foot 152 connected together by flexure structure 153. Flexure structure 153 has a forwardly extending strip 154 and a rearwardly extending strip 155 that form an X. When a force is applied to flexure structure 153, both forwardly extending strip 154 and rearwardly extending strip 155 flex.

[0109] Figure 12 is a schematic diagram of a flexure arrangement 200, where the arrangement is at rest or static, i.e., unloaded with no force applied, in Figure 12a, and flexed in Figure 12b, where a rotational force is applied. The diagram has a forward-extending strip 201 and a rearward-extending strip 202 connecting and extending between two blocks of material 203. When a force is applied, both the forward-extending strip 201 and the rearward-extending strip 202 flex, causing one block 203 to rotate about the other block 203. The pivot point is at the center of X.

[0110] Looking again at the single-piece hinge 150, when the single-piece hinge 150 is in the configuration for the raised or lowered position of the linkage set, the flexure structure is unloaded, and when the single-piece hinge 150 is in the configuration for the parked position of the linkage set, the flexure structure is flexed.

[0111] Figures 11b-d are detailed views of section A of Figure 11a in cross section, with Figure 11b in the raised position with the flexure arrangement 153 unloaded, Figure 11c in the parked position with the flexure arrangement 153 loaded, and Figure 11d in the lowered position with the flexure arrangement 153 again unloaded.

[0112] With particular reference to the details shown in Figures 13b and 13c, which show a cross section through line F in Figure 13a, it can be seen that flexure arrangement 153 comprises two forwardly extending strips 154 and one rearwardly extending strip 155. The forwardly extending strips 154 are on either side of the rearwardly extending strip 155, with gaps between each of the strips 154, 155 and between the strips 154 and the surrounding area of the single-piece hinge 150. In this way, there should be substantially no frictional forces to overcome to move the hinge between positions.

[0113] When the single-piece hinge 150 is configured so that the shin 151 is perpendicular to the foot 152, as shown in FIG. 13a, the shin 151 is fully engaged with the support area. The contact area between the shin 151 and foot 152 is designed to fit together. The support area is made up of the backrest 156 and shark's teeth 157 that extend from the foot 152. From this, loads transferred through the single-piece hinge 150 are directed around the flexure structure 153 and are transferred by the structural components of the single-piece hinge as the wheel is raised or lowered. Along the rear of the heel, there is a step or castellation 159 along the contact area of the backrest 156 to help ensure that the shin 151 and foot 152 come together properly and without twisting the flexure structure 153.

[0114] Similar to the single-piece hinges 130, 140, when the single-piece hinge 150 is in the parked position, the lower front or shin surface of the shin 151 rests against the top of the foot 152.

[0115] As mentioned above, the pivot point of flexure arrangement 153 is at the center of X. Outside of the single-piece hinge 150, this corresponds to the tip 158 where shin 151 meets foot 152 at the tip. The tip can swing between positions in the space between shark's tooth 157 and the front foot.

[0116] The single-piece hinge 150 cannot rotate past the vertical in a counterclockwise direction due to the backrest 156, and the single-piece hinge 150 cannot rotate past the top of the feet in a clockwise direction.

[0117] A letterbox or window 160 is located below the castellation 159 to reduce the overall weight of the single-piece hinge and allow better access to the flexure structure 153. For example, the window 160 can be used for removal of excess material during manufacturing and for inspection.

[0118] It should be appreciated that a turning mechanism for a load handling device may comprise a combination of different linkage sets of the type described herein using a series of single piece hinges, or one or more other types, such as compliant mechanisms, other flexure arrangements, or fixed pin pivot point linkage mechanisms.

[0119] FIG. 16 illustrates a diagram of an additive manufacturing process 210 for producing the single-piece hinges 130, 140, 150 and an assembly process 211 for assembling the single-piece hinges 130, 140, 150 into a linkage set and redirection assembly for a load handling device.

[0120] First, regardless of the particular manufacturing technique, a particular single-piece hinge 130, 140, 150 is designed as a digital model, for example, as a CAD file. The digital model file is exported 212 to an additive manufacturing device in a compatible format.

[0121] First, the additive manufacturing device uses build packing 213 software to enable parts to be optimally positioned in the device's build chamber. It should be recognized that the size and number of pieces that can be printed depends on the build chamber of the additive manufacturing device. Parts may be automatically positioned by the build packing software; however, the designer may manually intervene to place parts in a specific orientation within the build chamber.

[0122] Once the placement is determined, the build can then be uploaded to the printing software 214. In an SLS additive manufacturing machine, the print is constructed as "sliced" layers of material. During printing 215, powder material in the build chamber is heated to just below the material's melting point. A laser is used to push selected areas above the melting point and sinter the material. During the process, unsintered powder is left in place around the sintered material, acting as support for the sintered material.

[0123] The build chamber containing all of the parts is then removed 216. Optionally, the build chamber may be left in the manufacturing equipment to cool for a period of time before it is removed.

[0124] Once cooled, excess or unwanted powder is removed 217 from the part. The excess is unsintered support material. The excess is removed in a tumbling machine. Further excess material is removed manually. The single-piece hinges 130, 140, 150 are then ready for assembly.

[0125] Prior to assembly, when the single-piece hinges 130, 140, 150 are manufactured with first and second portions joined at the heel contacting portion, the joint is split to allow movement between the first and cross-sectional portions so that the single-piece hinge can move between the first and second positions.

[0126] The upper brace 123 is prepared for assembly 211 into the linkage set 120 with an aluminum shaft that acts as a pivot point. The single-piece hinges 130, 140, 150 are threaded 218 onto the upper brace 122 around the aluminum shaft. This process is repeated five times for the linkage set 120, which includes five single-piece hinges 130, 140, 150. It should be appreciated that the linkage set 120 can have two or more single-piece hinges 130, 140, 150, but a linkage set 120 with five single-piece hinges 130, 140, 150 is illustrated herein.

[0127] Similarly, the lower brace 122 is prepared with an aluminum shaft to act as a pivot point. The single-piece hinges 130, 140, 150 are threaded 219 onto the lower brace 123 around the aluminum shaft. This process is repeated for each of the single-piece hinges 130, 140, 150.

[0128] Finally, a cap plate is attached 220 to the upper brace 122 and a cap plate is attached 220 to the lower brace 123 to provide a fully assembled linkage set 221, substantially as described in connection with FIG. 7.

[0129] Four linkage sets 221, one on each side of the load handling device, may be assembled into a diverter assembly substantially as described in relation to FIG.

[0130] It should be appreciated that the various configurations of single-piece hinges described herein can be used in any number of applications in mechanical linkages. FIG. 15 illustrates a single-piece linkage 170 using two single-piece hinges. Similar to the examples described above, a first single-piece hinge 172 is formed at one end of a first portion 171, and a second single-piece hinge 173 is formed at a distal end of the first portion 171. From this, single-piece linkage 170 can be considered a dual single-piece hinge or linkage. Both single-piece hinges 172, 173 include a flexure structure 174.

[0131] 15a-i, which show various views and cross sections of single-piece linkage 170, the first single-piece hinge 172 and the second single-piece hinge 173 are arranged to rotate in the same direction, and thus the dual single-piece linkage 170 is an articulated (in this case, two-articulated) chain, resembling a finger. When both single-piece hinges 172, 173 flex, the single-piece linkage 170 will form an arch.

[0132] It should be appreciated that any number of additional single-piece hinges may be added to one or the other end of the chain. Furthermore, within an articulated chain or single-piece linkage, the flexure arrangements between each section of the chain may be configured to flex or bend in different directions. Still further, while the examples described and illustrated herein show the sections as substantially linear, it is anticipated that one or more sections may have a curved or complex shape.

[0133] Although an effort has been made in the foregoing specification to draw attention to those features of the invention which are considered to be particularly important, it is to be understood that the applicant claims protection for any patentable feature or combination of features referred to in this specification and / or shown in the drawings, whether or not specifically emphasized.

[0134] It should be appreciated that a single-piece hinge or single-piece linkage can be designed for a particular application using various combinations of the devices and configurations described above. It should be appreciated that all of the features described above may be used together in a single system. In other embodiments of the invention, some of the features may be omitted. The features may be used in any compatible configuration. Many variations and modifications not expressly described above are possible without departing from the scope of the invention as defined in the appended claims. The following is a summary of the claims as originally filed: [1] A single-piece hinge, a first portion and a second portion; a flexure structure connecting a first end of the first portion to a first end of the second portion; the single-piece hinge is rotatably movable about a pivot point at the first end of the first portion and movable between a first position and a second position; In the first position, rotation is limited by a first support area; In the second position, rotation is limited by a second support area, the single-piece hinge. [2] The single-piece hinge of [1], wherein the contact portions between the first and second portions in the first support region have complementary shapes. [3] The single-piece hinge according to [1] or [2], wherein the shape of the second part guides the first part into the first position. [4] The single-piece hinge of any one of [1] to [3], wherein the first support region of the second part has a shark tooth shape. [5] A single-piece hinge as described in any one of [1] to [4], wherein the contact portion between the first portion and the second portion in the second support region has a complementary shape. [6] The single-piece hinge of any one of [1] to [5], wherein the flexure structure is at least partially bounded on a lateral side by the first support region. [7] The single-piece hinge of any one of [1] to [6], wherein the flexure structure is at least partially nested within the first end of the first portion. [8] The single-piece hinge of any one of [1] to [7], wherein the flexure structure is at least partially nested within the first end of the second part. [9] A single-piece hinge as described in any one of [1] to [8], wherein the first part comprises a rocker at the first end of the first part and the second part comprises a socket, wherein the rocker is located within the socket.

[10] A single-piece hinge as described in any one of [1] to [9], wherein the flexure structure comprises one or more strips of material extending between the first portion and the second portion.

[11] The single-piece hinge of

[10] , wherein at least one strip extends in a first direction and at least one strip extends in a second direction substantially opposite the first direction.

[12] A single-piece hinge as described in any one of [1] to

[11] , wherein the flexure structure comprises a single strip extending in a first direction and two strips extending in a second direction, the single strip extending in the first direction having a width equal to the combined width of the two strips extending in the second direction.

[13] A single-piece hinge as described in any one of

[10] to

[12] , wherein each strip of the flexure structure is separated from other features by a gap on each side along its length.

[14] A single-piece hinge according to any one of [1] to

[13] , wherein the first part, the second part, and the flexure structure are formed from a single piece of material.

[15] The single-piece hinge of any one of [1] to

[14] , wherein the single-piece mechanism is 3D printed or constructed by additive manufacturing.

[16] The single-piece hinge according to any one of [1] to

[15] , wherein the first part further comprises a window for removing excess material.

[17] The single-piece hinge according to any one of [1] to

[16] , wherein the single-piece mechanism is used as a linkage set to convert horizontal force into vertical motion.

[18] The single-piece hinge according to any one of [1] to

[17] , wherein the linkage set comprises a direction change mechanism.

[19] A single-piece hinge according to any one of [1] to

[18] , wherein a second single-piece hinge is formed at a second end of the first part, distal to the first end of the first part, to form a double single-piece hinge linkage.

[20] A method for manufacturing a single-piece hinge according to any one of [1] to

[19] , the method comprising: printing a digital model of the single-part hinge using an additive manufacturing device; removing the printed single-part hinge from the additive manufacturing device; removing excess material from the single-piece hinge; A method comprising:

[21] A cargo handling device for lifting and moving storage containers stacked in a grid framework structure, the grid framework structure comprising a first set of parallel rails or tracks and a second set of parallel rails or tracks extending substantially perpendicular to the first set of parallel rails or tracks in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces, the grid being supported by a set of uprights to form a plurality of vertical storage locations beneath the grid such that containers are stacked between and guided by the set of uprights vertically through the plurality of grid spaces; The cargo handling device comprises: a body mounted on a first set of wheels configured to engage with the first set of parallel rails or tracks and a second set of wheels configured to engage with the second set of parallel rails or tracks; and a turning assembly configured to raise or lower the first set of wheels and / or lower or raise the second set of wheels relative to the body to engage and disengage the wheels with the parallel rails or tracks, the turning assembly comprising a linkage set comprising a series of single-piece hinges described in any one of [1] to

[19] arranged between a traveler and a fixed brace, the traveler being configured to move under an applied force to allow the wheels to be raised or lowered.

Claims

1. A single-piece hinge, a first portion and a second portion; a flexure structure connecting a first end of the first portion to a first end of the second portion; the single-piece hinge is rotatably movable about a pivot point at the first end of the first portion and is movable between a first position and a second position, in which rotation is limited by a first support area; In the second position, rotation is limited by a second support area; The first support area of the second portion has a shark tooth shape.

2. The single-piece hinge of claim 1 , wherein contact portions between the first and second portions at the first support area have complementary shapes.

3. 3. A single-piece hinge as claimed in claim 1 or 2, wherein the shape of the second part guides the first part into the first position.

4. 3. A single-piece hinge according to claim 1 or 2, wherein the contact portions between the first and second portions at the second support area have complementary shapes.

5. 3. The single-piece hinge of claim 1 or 2, wherein the flexure arrangement is at least partially bounded on a lateral side by the first support area.

6. 3. A single piece hinge as claimed in claim 1 or 2, wherein the flexure arrangement is at least partially nested within the first end of the first portion.

7. 3. A single piece hinge as claimed in claim 1 or 2, wherein the flexure arrangement is at least partially nested within the first end of the second portion.

8. 3. The single-piece hinge of claim 1 or 2, wherein the flexure arrangement comprises one or more strips of material extending between the first and second portions.

9. 9. The single-piece hinge of claim 8, wherein at least one strip extends in a first direction and at least one strip extends in a second direction substantially opposite the first direction.

10. 3. The single-piece hinge of claim 1 or 2, wherein the flexure arrangement comprises a single strip extending in a first direction and two strips extending in a second direction, the single strip extending in the first direction having a width equal to the combined width of the two strips extending in the second direction.

11. 3. The single piece hinge of claim 1 or 2, wherein the first portion, the second portion, and the flexure arrangement are formed from a single piece of material.

12. 3. The single-piece hinge of claim 1 or 2, wherein the single-piece mechanism is used as a linkage set to convert horizontal force into vertical movement.

13. The single piece hinge of claim 12 wherein the linkage set comprises a direction change mechanism.

14. 3. The single-piece hinge of claim 1 or 2, wherein a second single-piece hinge is formed at a second end of the first part distal to the first end of the first part, forming a double single-piece hinge linkage.

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