Systems and methods for condition-based maintenance

Abstract

A system and method for condition-based maintenance of an automated storage and retrieval system, the system comprising: a skeletal structure with a rail system forming a three-dimensional storage grid structure for storing storage containers for storing items, the grid structure forming vertical storage columns each having a horizontal area defined by the size of the access openings between the rails, the rail system disposed on the skeletal structure, the rail system providing an available path for a container handling vehicle; at least one container handling vehicle, the grid structure comprising one or more ports for extracting containers from the storage grid so that they can be loaded; and an inspection station for performing maintenance on components of the storage and retrieval system.

Description

[Technical Field]

[0001] The present invention relates to an automated storage and retrieval system for the storage and retrieval of containers, and more particularly to a system and method for an intelligent maintenance system that uses condition-based maintenance of components of the system. [Background technology]

[0002] FIG. 1 discloses a typical prior art automated storage and retrieval system 1 with a framework structure 100, and FIGS. 2 and 3 disclose two different prior art container handling vehicles 201, 301 suitable for operating on such a system 1.

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

[0004] The framework structure 100 of the automated storage and retrieval system 1 includes a rail system 108 disposed across the top of the framework structure 100, on which a plurality of container handling vehicles 201, 301 operate to raise, lower, and transport storage containers 106 up and down the storage columns 105. The rail system 108 includes a first set of parallel rails 110 disposed to guide movement of the container handling vehicles 201, 301 in a first direction X across the top of the framework structure 100, and a second set of parallel rails 111 disposed perpendicular to the first set of rails 110 for guiding movement of the container handling vehicles 201, 301 in a second direction Y that is perpendicular to the first direction X. The containers 106 stored in the columns 105 are accessed by the container handling vehicles through access openings 112 in the rail system 108. The container handling vehicles 201, 301 can move laterally above the storage columns 105, i.e. in a plane that is parallel to the horizontal XY plane.

[0005] The uprights 102 of the skeletal structure 100 can be used to guide the storage containers during their ascent out of and descent into the columns 105. The stacks 107 of containers 106 are typically freestanding.

[0006] Each prior art container handling vehicle 201, 301 includes a body 201a, 301a and first and second sets of wheels 201b, 301b, 201c, 301c, respectively, that allow lateral movement of the container handling vehicle 201, 301 in the X and Y directions. In Figures 2 and 3, two wheels in each set are fully visible. The first set of wheels 201b, 301b are positioned to engage two adjacent rails of the first set of rails 110, and the second set of wheels 201c, 301c are positioned to engage two adjacent rails of the second set of rails 111. At least one of the sets of wheels 201b, 301b, 201c, 301c can be raised and lowered so that the first set of wheels 201b, 301b and / or the second set of wheels 201c, 301c can be engaged with the respective set of rails 110, 111 at any one time.

[0007] Each prior art container handling vehicle 201, 301 also includes a lifting device (not shown) for vertically transporting the storage containers 106, e.g., lifting the storage containers 106 from the storage columns 105 and lowering them into the storage columns 105. The lifting device includes one or more gripping / engaging devices adapted to engage the storage containers 106, which can be lowered from the vehicle 201, 301 so that the position of the gripping / engaging devices relative to the vehicle 201, 301 can be adjusted in a third direction Z, which is orthogonal to the first direction X and the second direction Y. A portion of the gripping device of the container handling vehicle 301 is shown in FIG. 3 and designated with reference numeral 304. The gripping device of the container handling device 201 is located within the vehicle body 301a of FIG. 2.

[0008] As is conventional, for purposes of this application, Z=1 identifies the top layer of storage containers, i.e., the layer immediately below rail system 108; Z=2 identifies the second layer below rail system 108; Z=3 identifies the third layer, etc. In the exemplary prior art disclosed in FIG. 1 , Z=8 identifies the lowest bottom layer of storage containers. Similarly, X=1·n and Y=1·n identify the position of each storage column 105 in the horizontal plane. Consequently, using the Cartesian coordinate system X, Y, Z shown in FIG. 1 as an example, a storage container identified as 106′ in FIG. 1 may be said to occupy storage location X=10, Y=2, Z=3. Container handling vehicles 201, 301 may be said to travel in layer Z=0, and each storage column 105 may be identified by its X and Y coordinates.

[0009] The storage volume of the skeleton structure 100 is often referred to as a grid 104, and the possible storage locations within this grid are referred to as storage cells. Each storage column may be identified by a position in the X and Y directions, while each storage cell may be identified by a container number in the X, Y, and Z directions.

[0010] Each prior art container handling vehicle 201, 301 includes a storage compartment or space for receiving and storing the storage containers 106 as they are transported across the rail system 108. The storage space may include a centrally located cavity within the vehicle body 201 a, as shown in FIG. 2 and as described, for example, in WO 2015 / 193278 A1, the contents of which are incorporated herein by reference.

[0011] 3 shows an alternative configuration of a container handling vehicle 301 with a cantilever structure. Such a vehicle is described in detail, for example, in No. 317366, the contents of which are also incorporated herein by reference.

[0012] 2 may have a footprint covering an area with dimensions in the X and Y directions generally equal to the lateral extent of a storage column 105, as described, for example, in WO 2015 / 193278 A1, the contents of which are incorporated herein by reference. As used herein, the term "lateral" may mean "horizontal."

[0013] Alternatively, the central hollow container handling vehicle 101 may have a footprint that is larger than the lateral area defined by the storage columns 105, for example as disclosed in WO2014 / 090684A1.

[0014] Rail system 108 typically includes rails with grooves along which vehicle wheels run. Alternatively, the rails may include upwardly protruding elements, and the vehicle wheels may include flanges to prevent derailment. These grooves and upwardly protruding elements are collectively known as tracks. Each rail may include one track, or each rail may include two parallel tracks.

[0015] WO2018146304 (Patent Document 1), the contents of which are incorporated herein by reference, illustrates a typical configuration of a rail system 108 comprising rails and parallel tracks in both the X and Y directions.

[0016] WO 2019 / 238702 (Patent Document 2) discloses an automated storage and retrieval system comprising a skeletal structure with a rail system forming a three-dimensional storage grid for storing containers for storing items, the grid structure forming vertical storage columns each having a horizontal area defined by the size of the access openings between the rails of the rail system arranged on the skeletal structure, and the rail system providing available paths for container handling vehicles to handle and transport the storage containers to and from the storage columns.

[0017] US2014 / 207726 (Patent Document 3) describes a system for recommending the maintenance of helicopter engines according to the technical condition of the engine, the standard exchange of parts between engines, and the exchange of parts with different parts.

[0018] In the skeleton structure 100, the majority of the columns 105 are storage columns 105, i.e., columns 105 where storage containers 106 are stored in stacks 107. However, some columns 105 may have other purposes. In FIG. 1 , columns 119 and 120 are such special-purpose columns used by container handling vehicles 201, 301 to unload and / or load storage containers 106 so that they can be transported to access stations (not shown) where they can be accessed from outside the skeleton structure 100 or transferred out of or into the skeleton structure 100. Within the art, such locations are typically referred to as "ports," and the columns in which the ports are located may be referred to as "port columns" 119, 120. Transport to the access stations may be in any direction: horizontal, diagonal, and / or vertical. For example, storage containers 106 may be installed in random or dedicated columns 105 within the framework structure 100 and then loaded by any container handling vehicle and transported to port columns 119, 120 for further transport to an access station. Note that the term "diagonal" refers to the transport of storage containers 106 having some general transport orientation between horizontal and vertical.

[0019] In FIG. 1 , the first port column 119 may be, for example, a dedicated unloading port column where container handling vehicles 201, 301 may unload storage containers 106 to be transported to an access or transfer station, and the second port column 120 may be a dedicated loading port column where container handling vehicles 201, 301 may load storage containers 106 being transported from an access or transfer station.

[0020] An access station may typically be a picking station or a stockpiling station where product items are removed from or placed into storage containers 106. At a picking or stockpiling station, the storage containers 106 are typically not removed from the automated storage and retrieval system 1, but are accessed and then placed back into the backbone structure 100. A port may also be used to transfer storage containers to another storage facility (e.g., to another backbone structure or to another automated storage and retrieval system), to a transport vehicle (e.g., a train or lorry), or to a production facility.

[0021] A conveyor system comprising conveyors is typically employed to transport storage containers between the port columns 119, 120 and the access stations.

[0022] If the port columns 119, 120 and the access stations are located at different levels, the conveyor system may include a lifting device with a vertical component for transporting the storage containers 106 vertically between the port columns 119, 120 and the access stations.

[0023] The conveyor system may be arranged to transport the storage containers 106 between different skeletal structures, for example as described in WO2014 / 075937A1, the contents of which are incorporated herein by reference.

[0024] 1 is to be accessed, one of the container handling vehicles 201, 301 is commanded to retrieve the target storage container 106 from its location and transport it to the unloading port column 119. This operation involves moving the container handling vehicle 201, 301 to a location above the storage column 105 where the target storage container 106 is located, using a lifting device (not shown) of the container handling vehicle 201, 301 to retrieve the storage container 106 from the storage column 105, and transporting the storage container 106 to the unloading port column 119. If the target storage container 106 is located deep within the stack 107, i.e., with one or more other storage containers 106 positioned above the target storage container 106, the operation also involves temporarily moving the storage container(s) positioned above it prior to lifting the target storage container 106 from the storage column 105. This step, sometimes referred to within the art as "digging," may subsequently be performed using the same container handling vehicle used to transport the target storage container to the unloading port column 119, or using one or more other cooperating container handling vehicles. Alternatively, or in addition, the automated storage and retrieval system 1 may have a container handling vehicle specifically dedicated to the task of temporarily removing storage containers from storage columns 105. Once the target storage container 106 is removed from storage column 105, the temporarily removed storage container can be repositioned in the original storage column 105. However, the removed storage container may alternatively be repositioned in another storage column.

[0025] When a storage container 106 is to be stored in one of the columns 105, one of the container handling vehicles 201, 301 is commanded to load the storage container 106 from the load port column 120 and transport it to a location above the storage column 105 where it is to be stored. After any storage containers positioned at or above the target location in the storage column stack 107 are removed, the container handling vehicles 201, 301 position the storage container 106 in the desired location. The removed storage container can then be lowered back into the storage column 105 or repositioned to another storage column.

[0026] To monitor and control the automated storage and retrieval system 1, for example, to monitor and control the location of each storage container 106 within the skeletal structure 100, the contents of each storage container 106, and the movements of the container handling vehicles 201, 301 so that the desired storage containers 106 can be delivered to the desired locations at the desired times without the container handling vehicles 201, 301 colliding with each other, the automated storage and retrieval system 1 typically includes a control system 500 that is computerized and typically includes a database for tracking the storage containers 106.

[0027] The problem with this solution is that if, for example, a container handling vehicle breaks down while performing a task on the grid, it causes enormous problems because the entire grid needs to be shut down while the container handling vehicle is maintained. This is the same for all of the different parts of the storage system. If a part or component of the storage system breaks down, the consequences are great for the entire system because it causes delays in the operation of the storage system. And when you have a storage system with hundreds of container handling vehicles, a one-hour shutdown of operation results in a huge financial loss.

[0028] It is therefore an object of the present invention to solve the problems stated above. [Prior art documents] [Patent documents]

[0029] [Patent Document 1] International Publication No. 2018 / 146304 [Patent Document 2] International Publication No. 2019 / 238702 [Patent Document 3] US Patent Application Publication No. 2014 / 207726 Summary of the Invention [Means for solving the problem]

[0030] The present invention is set forth and characterized in the independent claims, while the dependent claims describe further characteristics of the invention.

[0031] In one aspect, the present invention provides a system for condition-based maintenance of an automated storage and retrieval system, the system comprising: a skeletal structure with a rail system forming a three-dimensional storage grid structure for storing storage containers for storing items, the grid structure forming vertical storage columns each having a horizontal area defined by the size of an access opening between the rails of the rail system disposed on the skeletal structure, the rail system providing available paths for container handling vehicles to handle and transfer the storage containers to and from the storage columns; at least one container handling vehicle having a container handling platform with a set of grippers for handling the storage containers, the grid structure comprising one or more ports for extracting containers from the storage grid so that they can be loaded; an inspection station for performing maintenance on components of the storage and retrieval system; and an inspection implementation plan manager configured to retrieve condition-based information linked to parts and components of the storage and retrieval system, analyze the retrieved condition-based information, generate an inspection implementation plan based thereon, and transmit the inspection implementation plan to the inspection station.

[0032] The solution to the above objective is therefore to collect as much information as possible about the condition of the different parts of the system and use this information to predict when inspection or other maintenance is necessary. If the parts and components of the system are regularly repaired and maintained, the storage system will not have to be partially or completely shut down due to a malfunctioning robot, and economic losses will be significantly less. The system therefore needs to collect information from many different sources, not only by constant supervision, but also by collecting information about each component of the system and / or from many different sources.

[0033] The system includes a global computer system configured to collect and analyze information from the central computer system of each individual storage and retrieval system, production and testing facilities, and inspection contractors, and to transmit relevant information back to the central computer system of each individual storage and retrieval system.

[0034] Accordingly, the storage system may further include sensors attached to the components to provide condition-based information. The sensors may include temperature and / or humidity sensors. The sensors may include load sensors. The sensors may include movement sensors.

[0035] The service center may be configured to record and store a data record when a component fails, the data record including information related to the component, its service time, and / or age.

[0036] A container handling vehicle with a worn component may also be instructed by the central computer system to adapt its speed, acceleration, and deceleration to suit the component condition. For example, it may be instructed to reduce its maximum speed, reduce its average speed, reduce its acceleration, and / or reduce its deceleration. The container handling platform on the container handling vehicle has sensors to detect when a storage container is experiencing significant resistance or is stuck within a storage container column of the storage system. Location details of where the container handling vehicle is experiencing increased resistance or is stuck within a storage column may be fed back to the central computer system and / or an inspection scheduling manager.

[0037] At least one container handling vehicle may have at least one rechargeable power source. The automated storage and retrieval system may include at least one charging device for charging the rechargeable power source of the container handling vehicle.

[0038] A second aspect of the present invention is directed to a method for condition-based maintenance of an automated storage and retrieval system, the system comprising: a skeletal structure with a rail system forming a three-dimensional storage grid structure for storing storage containers for storing items, the grid structure forming vertical storage columns each having a horizontal area defined by the size of an access opening between the rails of the rail system disposed on the skeletal structure, the rail system providing an available path for a container handling vehicle to handle and transfer the storage containers to and from the storage columns; and at least one container handling vehicle having a container handling platform with a set of grippers for handling the storage containers, the grid structure providing an available path for a container handling vehicle to handle and transfer the storage containers to and from the storage columns; and at least one container handling vehicle equipped with one or more ports for extracting containers from a storage grid so as to accommodate the containers, and an inspection station for performing maintenance on components of the storage and retrieval system, the method comprising the steps of: monitoring the condition of the components of the storage and retrieval system; transmitting information about the condition of the components of the storage and retrieval system to a central computer system; analyzing the information about the condition of the components of the storage and retrieval system using an inspection implementation plan manager; generating an inspection implementation plan based on the analyzed information about the condition of the components of the storage and retrieval system; and transmitting the inspection implementation plan to at least one inspection station where the condition-based maintenance is performed.

[0039] Additionally, the method may include collecting information from sensors monitoring components of the storage and retrieval system, which may include a register of problems with the components of the storage and retrieval system, along with information regarding their service time and age.

[0040] The method may also include assigning the container handling vehicle having the worn component to a less demanding task on a task list. The container handling vehicle may be instructed to adapt its speed, acceleration, and / or deceleration to suit the condition of the worn component. For example, it may be instructed to reduce its maximum speed, reduce its average speed, reduce its acceleration, and / or reduce its deceleration.

[0041] In embodiments having sensors mounted on gripper elements on container handling platforms of container handling vehicles to detect when storage containers encounter significant resistance or become stuck within a storage container column of a storage and retrieval system, information regarding the location of where a storage container encountered significant resistance or became stuck can be fed back to a central computer system and / or an inspection scheduling manager. Information from production and testing facilities can be updated and sent to the central computer system. Information from inspection contractors can be updated and sent to the central computer system.

[0042] By doing this, the present invention, at least in the preferred embodiment, describes a system where information is collected from many different sources and used to generate inspection protocols with the sole intention of preventing unintended breakdowns of the materials and configurations of the different parts of the storage and retrieval system.

[0043] The intention here is to be proactive and maximize the utility of all components with minimal risk. The solution is to catch problems before they become big problems. The present invention provides, for example, the following. (Item 1) 1. A system for condition-based maintenance of an automated storage and retrieval system, the system comprising: a framework (100) with a rail system, said framework (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items; the grid structure (104) forms vertical storage columns (105), each having a horizontal area defined by the size of an access opening (112) between the rails of the rail system (108) disposed on the framework structure (100); the rail system (108) comprises a framework (100) that handles the storage containers (106) and provides an accessible path for container handling vehicles (201) that transport the storage containers (106) to and from the storage columns (105); at least one container handling vehicle (201, 301), said at least one container handling vehicle (201, 301) having a container handling platform (500) with a set of grippers for handling said storage containers (106); at least one container handling vehicle (201, 301), the grid structure having one or more ports for extracting containers (106) from the storage grid so that they can be loaded; an inspection station (502) for performing maintenance on components of said storage and retrieval system (1); Equipped with The system is further characterized by comprising a central computer system (503) and an inspection schedule manager (507); The inspection execution plan manager (507) is configured to retrieve condition-based information linked to parts and components of the storage and retrieval system, analyze the retrieved condition-based information, generate an inspection execution plan based thereon, and transmit the inspection execution plan to the inspection station (502) where condition-based maintenance is performed. (Item 2) The system described in item 1, wherein the at least one container handling vehicle (201, 301, 401) has at least one rechargeable power source (405), and the system has at least one charging device for charging the rechargeable power source of the container handling vehicle (201, 301, 401). (Item 3) 2. The system of claim 1, wherein the storage and retrieval system (1) comprises a sensor (501) attached to a component for providing the condition-based information. (Item 4) Item 10. The system of item 1, comprising a global computer system configured to collect and analyze information from the central computer system of each individual storage and retrieval system, production and testing facilities, and inspection vendors, and to transmit relevant information back to the central computer system of each individual storage and retrieval system. (Item 5) Item 4. The system of item 3, wherein the sensor (501) comprises a temperature sensor and / or a humidity sensor. (Item 6) 6. The system of claim 1, 3, or 5, wherein the inspection center (502) is configured to record and store a data record when a component fails, the data record comprising information related to the component, its inspection time, and / or age. (Item 7) 7. The system of any of items 1-6, wherein a container handling vehicle (201, 301, 401) with worn components is instructed by the central computer system to adapt its speed, acceleration, and deceleration to suit the component condition. (Item 8) 8. The system according to any of items 1-7, wherein the container handling platform of the container handling vehicle (201, 301) has a sensor (501) that detects when a storage container (106) encounters resistance or becomes stuck within a storage container column of the storage and retrieval system (1). (Item 9) 1. A method for condition-based maintenance of an automated storage and retrieval system, comprising: The system comprises: a framework (100) with a rail system, said framework (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items; the grid structure (104) forms vertical storage columns (105), each having a horizontal area defined by the size of an access opening (112) between the rails of the rail system (108) disposed on the framework structure (100); the rail system (108) comprises a framework (100) that handles the storage containers (106) and provides an accessible path for container handling vehicles (201) that transport the storage containers (106) to and from the storage columns (105); at least one container handling vehicle (201, 301), said at least one container handling vehicle (201, 301) having a container handling platform (500) with a set of grippers for handling said storage containers (106); at least one container handling vehicle (201, 301), the grid structure having one or more ports for extracting containers (106) from the storage grid so that they can be loaded; an inspection station (502) for performing maintenance on components of said storage and retrieval system (1); Equipped with The method comprises: - monitoring the condition of components of said storage and retrieval system; - transmitting information about the condition of said components of said storage and retrieval system to a central computer system; - analyzing said information regarding the condition of said components of said storage and retrieval system using an inspection schedule manager (506); - generating an inspection implementation plan based on the analyzed information regarding the condition of the components of the storage and retrieval system; - transmitting said inspection execution plan to at least one inspection station (502); - performing condition-based maintenance when required; A method comprising: (Item 10) 10. The method of claim 9, wherein the method includes collecting information from sensors (601) monitoring components of the storage and retrieval system (1). (Item 11) 11. The method of claim 10, wherein the information from the sensors comprises a register of problems with the components of the storage and retrieval system, along with information regarding their service time and age. (Item 12) 11. The method according to item 9 or 10, wherein the method comprises allocating a container handling vehicle (201, 301, 401) having worn components to a less demanding task on a task list. (Item 13) 13. The method according to any of items 9-12, wherein the method comprises adapting the speed, acceleration and deceleration of a container handling vehicle (201, 301, 401) with a worn component to suit the condition of the worn component. (Item 14) 14. The method according to any one of items 9-13, wherein the method comprises attaching a sensor (501) to the gripper element of a container handling platform of a container handling vehicle (201, 301), the sensor (501) detecting when a storage container (106) is stuck within a storage container column of the storage and retrieval system (1). (Item 15) 15. The method of any one of items 9-14, wherein the method includes updating (608) information from production and test facilities (504) and transmitting the updated information to the central computer system (503). (Item 16) 16. The method of any one of items 9-15, wherein the method includes updating (609) information from an inspection vendor and transmitting the updated information to the central computer system (503). [Brief explanation of the drawings]

[0044] The following drawings are included to facilitate an understanding of the invention: The drawings illustrate embodiments of the invention which will now be described by way of example only.

[0045] [Figure 1] FIG. 1 is a perspective view of a three-dimensional storage grid structure of a prior art automated storage and retrieval system. [Figure 2] FIG. 2 is a perspective view of a prior art container handling vehicle having a centrally located cavity for carrying storage containers therein. [Figure 3] FIG. 3 is a perspective view of a prior art container handling vehicle having a cantilever beam for transporting storage containers underneath. [Figure 4] FIG. 4 is a perspective view of a prior art container handling vehicle in the form of a container handling vehicle on which a container may be transported. [Figure 5] FIG. 5 is a box diagram of one embodiment of a system in which the active components of the system are displayed and how they work together. [Figure 6] FIG. 6 is an exemplary step-by-step flowchart of one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0046] In the following, embodiments of the present invention will be discussed in more detail with reference to the accompanying drawings, in which it should be understood, however, that the drawings are not intended to limit the invention to the subject matter depicted in the drawings.

[0047] The skeleton structure (100) with a rail system forming the three-dimensional storage grid structure (104) of the automated storage and retrieval system 1 is constructed in accordance with the prior art skeleton structure 100 described above in connection with Figures 1-4, i.e., several upright members 102 and several horizontal members 103 supported by the upright members 102, and further, the skeleton structure 100 is provided with a first upper rail system 108 in the X and Y directions.

[0048] Skeleton structure 100 further comprises storage compartments in the form of storage columns 105 provided between members 102 and 103, with storage containers 106 stackable in stacks 107 within storage columns 105.

[0049] Skeleton structure 100 can be of any size. In particular, it should be understood that skeletal structure can be significantly wider and / or longer and / or deeper than that disclosed in Figure 1. For example, skeletal structure 100 can have a horizontal extent of greater than 700 x 700 columns and a storage depth of greater than 12 containers.

[0050] In Figures 2-4 different container handling vehicles are shown, in Figure 2 a container handling vehicle with a central cavity solution is shown, where the containers are transported in a central cavity within the container handling vehicle.

[0051] In Figure 3 a container handling vehicle with a cantilever support solution is shown, where the containers are carried by a lifting frame mounted adjacent to the main body of the container handling vehicle.

[0052] In Figure 4, the container handling vehicle is shown in the form of a delivery vehicle, which is a container handling vehicle on which the container is carried.

[0053] All vehicles have eight wheels: four for moving the vehicle in the X direction and four for moving the vehicle in the Y direction.

[0054] FIG. 5 is a box diagram of one embodiment of the present invention, showing the active components of the system and how they are connected.

[0055] The storage and retrieval system as a whole is made up of several different parts and components that work together to make the system operate. Some of these parts and components are subject to wear and tear, either because they are moving parts or because they are subject to strain and temperature changes. Examples of such parts or components are the moving parts on a container handling vehicle (such as the wheels and parts that lift the wheels and control their movement), as well as the components within the lift platform of a container handling vehicle.

[0056] Additionally, there may be sensors 501 attached to moving parts of ports and loading stations where container handling vehicles deliver containers and items in the containers are loaded for further distribution. Sensors 501 may be provided in barriers that separate different storage grids from each other and parts of the grids from other parts of the storage grids, the sensors 501 for monitoring the condition of the components.

[0057] To track the condition of components or parts, sensors 501 can be installed on or in association with them to register whether the part or component shows signs of deterioration. If the part or component shows signs of deterioration, the sensor registers that information and transmits it onward, i.e., to a local inspection system or a central computer system 503, which can decide what to do in this situation.

[0058] An example of a sensor 501 that may be used is a temperature sensor 501 that may measure the temperature of a component to check if there is an abnormal generation of heat from the component. There may also be an accelerometer attached to the component to check if there is any abnormal movement within the component. The abnormal movement may be, for example, that the component is vibrating. The energy consumption of parts of the system may also be monitored. Higher than normal energy consumption may be a signal that there is an abnormality in the component. The sensor 501 may also be a microphone that measures the sound that the part or component is making. The speed at which the part or component is moving may also be measured by the sensor.

[0059] In one embodiment of the invention, sensors 501 transmit their information to an inspection station 502, for example, a local inspection station located on-site and connected to the rail system. The local inspection station 502 can be the location where all maintenance of the system is managed and where information regarding the condition of parts and components is stored. The stored information can be information transmitted from sensors 501 or it can be information collected during repairs performed on the storage and retrieval system. The local inspection station 502 stores the information and tracks the wear and tear of components. The local inspection station 502 communicates the collected information to a central computer system 503. This embodiment has an inspection and maintenance computer system that is separate from the central computer system 503 and managed from the local inspection station 502.

[0060] In an alternative embodiment of the present invention, all of the information transmitted from sensors 501 can be transmitted to a central computer system 503. In this solution, central computer system 503 collects all information from its storage and retrieval system and tracks the condition of the components and parts of the storage and retrieval system as well as any maintenance that needs to be done. In this embodiment, the entire inspection and maintenance system is part of central computer system 503.

[0061] Condition-based information is information collected from sensors 501 monitoring components and parts of at least one storage and retrieval system. Additionally, it includes information collected from inspection providers regarding wear and tear found on system components. Condition-based information is also information collected from the production and testing 504 department. This information may be design or production defects found on components and parts during equipment testing and inspection. An example of such information may be a problem with a batch of circuit boards, etc. This information can be distributed to storage and retrieval systems that use a particular part or component, and the inspection execution plan manager 506 can consider this information when creating inspection execution plans.

[0062] The central computer system 503 determines the information to be transmitted on the global computer system 507. While information of interest to other storage and retrieval systems can be transmitted to the global computer system 507, information describing malfunctions due to occurrences or conditions unique to a particular storage and retrieval system may not be transmitted to the global computer system 507. Information that is not typically transmitted may be damage to a part or component on a container handling vehicle due to a collision or damage caused by human error. In contrast, information that is transmitted to the global computer system 507 is information that may help other storage and retrieval systems develop inspection protocols that may predict inspections for parts and components of interest. Examples of information of interest are a record of the component's age, the time the component was inspected, the conditions under which it was operating, and transmitting this information when the component begins to show signs of wear and tear or if it fails. This information may help the global computer system 507 predict the lifespan of the part or component and notify the storage and retrieval systems when the part needs to be inspected and maintained to avoid complications and costly damage to container handling vehicles or other components of the storage and retrieval system on the grid.

[0063] The global computer system 507 collects information from multiple storage and retrieval systems in order to have as much of a base as possible on which to base their evaluations and calculations: information about the type of component or part, the type of problem, the age of the component or part, the time the component was serviced and the conditions under which it has been operating, and any other information that may be of interest.

[0064] Based on this information, the global computer system 507 can discover trends regarding wear and tear on components. These trends can help indicate when a part or component needs maintenance or modification.

[0065] The evaluation is to determine which components may have problems, which components may not, and whether they tend to show signs of wear and tear.

[0066] Additionally, the global computer center receives information from production and testing 504, which can provide information such as design flaws that affect component performance and durability. For example, if a defective circuit board is present, batch numbers and other information of interest can also be collected by the production and testing 504 department.

[0067] The global computer system 507 also receives information from the inspection contractor 505 regarding the components that have been repaired or changed, along with when and where the changes were made.

[0068] The collected information is analyzed by the global computer system 507 to see if there are any trends that may indicate component problems. The results of the analysis are sent to the storage and retrieval system's central computer system 503.

[0069] The central computer system 503 can communicate information to its inspection execution plan manager 506 based on the information sent from the global computer system 507. The inspection execution plan manager 506 can be part of the central computer system 503 or it can be part of a separate inspection system, which can even be a separate stand-alone system independent of all other systems that control and operate the storage and retrieval system. The inspection execution plan manager 506 generates an inspection execution plan based on the information.

[0070] The inspection schedule controls when parts and components of the storage grid should be maintained. The inspection schedule manager 506 is periodically updated with new information, and therefore the inspection schedule is also updated with new information about what needs to be maintained and changed.

[0071] As an alternative to servicing or changing a component or part that shows signs of wear and tear, the worn component and the equipment to which it is attached can be commanded to operate at a reduced operating speed, for example, to place less load on the component or part. For example, a container handling vehicle can be commanded to operate at a reduced speed, or to carry less weight, or to accelerate or decelerate more slowly. This ensures the best use of the component or part, keeping both lifespan and economy in mind.

[0072] Additionally, there may be sensors 501 mounted around the inside of the building housing the storage and retrieval system to monitor the temperature and humidity inside the building. This allows the system to monitor if certain temperature or humidity ranges are present that cause more wear and tear on the components.

[0073] FIG. 6 is a flow chart of an exemplary step-by-step process of one embodiment of the present invention.

[0074] Sensors 501 transmit information regarding the condition of the components, which is transmitted to either a central computer system 503 or a local inspection station 502 that is part of the component storage and retrieval system.

[0075] If there is an anomaly, the part is evaluated to see if it can continue to operate at a reduced capacity or not. If not, the component or part is serviced or modified.

[0076] A central computer system 503 or local inspection stations 502 analyze the information and send it to a global database that collects information from multiple different storage and retrieval systems. Additionally, information is collected from production and testing facilities 504 or from inspection contractors 505 that handle repairs and maintenance on the storage and retrieval systems.

[0077] The global database collects all this information and analyzes it. Based on this analysis, information about the different components is sent back to the central computer system 503 or the local inspection stations 502. The central computer system 503 or the local inspection stations 502 analyzes the information and sends it to the inspection execution plan manager 506, which generates an inspection execution plan based on the information. The inspection execution plan is sent back to the central computer system 503 or the local inspection stations 502.

[0078] The inspection schedule includes information about which components to change and maintain and when to do so.

[0079] The inspection schedule is updated periodically as information from sensors 501 and production and test 504 equipment and inspection vendors 505 is periodically fed into the system.

[0080] In an alternative solution, information gathered from sensors 501 and local inspection stations 502 can be analyzed locally, and information from inspection contractors 505 and production and test 504 facilities is fed into each storage and retrieval system. An inspection execution plan manager 506 then generates inspection execution plans from the information gathered from the storage and retrieval systems it monitors. Information from other systems is not used as a basis for the inspection execution plans, or is not used generally.

[0081] The present invention can also be used to estimate the condition of a grid. The grid can be estimated down to each individual column level. If a problem exists in one of the columns, this will be indicated in the condition estimate for that column. The system can use this information to reduce wear and tear on container handling vehicles. If there is an alternate container that can be used, the container handling vehicle can be sent to obtain the alternate container. If there is no alternate container, the container handling vehicle can be instructed to reduce the speed at which the container is being lifted. If there is a column or series of columns that indicates a problem, the container handling vehicles can be instructed to proceed around the affected column or they can be instructed to use a reduced speed when driving within the affected area.

[0082] Containers are subject to a lot of wear and tear. There is a lot of wear and tear when they are lifted and lowered into the column, and they are also subjected to a lot of static pressure as they are stacked on top of each other in the column. The contents of the container can also become problematic due to the movement of items within the container as it is handled. If a container problem is indicated, the system can select a replacement container, if possible. If the container's condition suddenly changes from good to bad, the system can indicate an inspection of the container. This can be done via a camera mounted on the container handling vehicle. Alternatively, the container can be sent to the port for inspection by an operator. Furthermore, the container can even be placed in an area with little activity to reduce the number of times it is moved. Defective containers can be placed on columns that are not used often. It is also possible to place several defective containers in one area to minimize the impact they have on the efficiency of the automated storage and retrieval system.

[0083] If a port is indicated as having a problem, the central computer system can reduce the workload of the port showing the problem.

[0084] The communication system can also be monitored. If an area is registered where there are poor communications due to many inaccurate transmissions, the inspection system can indicate that the communication equipment in that area is malfunctioning and needs to be either serviced or changed. This can also be an indication that there is something disrupting wireless communication within that portion of the automated storage and retrieval system. By using condition-based estimation, it is possible to address wireless problems.

[0085] Additionally, chargers can be monitored and if the charger shows an indication of degraded performance, such as if it uses longer times to charge the batteries of a container handling vehicle, condition-based maintenance can be used to indicate the need for maintenance. In a charger, dirt in the filter could be the reason the charger is not charging to full effectiveness.

[0086] Additionally, chargers have connection points. Container handling vehicles attach to these connection points when they need to recharge their batteries. When they finish charging, they detach themselves from the connection points. Both the charging station and the container handling vehicle have connection points to which they attach when charging. The container handling vehicle uses power from its electric motor to maneuver to attach and detach from the charging station. Attaching and detaching several container handling vehicles to and from the charging station throughout the day will eventually cause wear on the charging points. Both the container handling vehicle connection points and the charger connection points are subject to wear. However, because there are typically more container handling vehicles than chargers, there is more wear on the charger than on the container handling vehicles.

[0087] There are ways to check if either the container handling vehicle or the connection points on the charger have worn to the point that they need to be changed. The container handling vehicle can measure the amount of power and torque required to disconnect from the charger. If the container handling vehicle needs to use power or torque above a preset threshold level, the container handling vehicle can try being attached to and removed from different chargers to determine if it is the connection point on the charger or the container handling vehicle connection point that needs to be changed.

[0088] The container handling vehicle can then provide information to the central computer system whether the connection points of the container handling vehicle need to be changed or whether one of the connection points of the charger needs to be changed. This solution allows the system to have continuous supervision of the connection points of both the charger and the container handling vehicle.

[0089] A sensor on the battery may indicate that the battery's charge capacity is decreasing. Examples may be that the battery is not able to be fully charged, or that the charge level drops rapidly during use. During busy periods such as Christmas and Black Friday, the reduced effectiveness of the battery will significantly affect the overall performance of the storage and retrieval system.

[0090] Storage and retrieval systems can process vast amounts of data and use machine learning to capture connections that regular computer systems are not able to capture.

[0091] The local computer system can control the container handling vehicles or other parts of the storage and retrieval system used to reduce the risk of failure or reduced capacity or collisions between container handling vehicles. Additionally, if a problem with the grid structure exists, the portion of the grid structure with the problem can be shut down or blocked to ensure that the grid is not further disrupted.

[0092] If a container handling vehicle needs maintenance, the container handling vehicle can also be ordered to retrieve a container with a spare part before proceeding to the maintenance area. If there are two or more container handling vehicles needing maintenance, one of the container handling vehicles can be used to obtain a container with a spare part before being sent to the maintenance area.

[0093] In the preceding description, various aspects of the delivery vehicle and automated storage and retrieval system according to the present invention have been described with reference to illustrative embodiments. For purposes of explanation, specific numbers, systems, and configurations have been set forth 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, and other embodiments of the system, that are obvious to those skilled in the art to which the disclosed subject matter pertains, are deemed to be within the scope of the present invention.

[0094] (List of reference numbers) [Table 1]

Claims

1. 1. A system for condition-based maintenance, the system comprising: an automated storage and retrieval system; a skeletal structure (100) with a rail system, said skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items; the grid structure (104) forms vertical storage columns (105), each of the vertical storage columns (105) having a horizontal area defined by the size of an access opening (112) between the rails of the rail system (108) disposed on the framework structure (100); the rail system (108) provides an available path for container handling vehicles (201) to handle the storage containers (106) and transport the storage containers (106) to and from the vertical storage columns (105); a skeletal structure (100); at least one container handling vehicle (201, 301), said at least one container handling vehicle (201, 301) having a container handling platform (500) with a set of grippers for handling said storage containers (106); The grid structure includes one or more ports for extracting containers (106) from the storage grid so that they can be loaded. at least one container handling vehicle (201, 301); an inspection station (502) for performing maintenance on components of said storage and retrieval system (1); Equipped with said storage and retrieval system comprising: a plurality of sensors (501) configured to be attached to components of the storage and retrieval system to provide condition-based information linked to parts and components of the storage and retrieval system; Inspection Implementation Plan Manager (507) and the inspection schedule manager is configured to collect condition-based information from the plurality of sensors, create inspection schedules based on the condition-based information linked to parts and components of the storage and retrieval system, and transmit the inspection schedules to local inspection stations (502) where condition-based maintenance is to be performed; The system further comprises a central computer system (503); the central computer system (503) is configured to receive the condition-based information from the plurality of sensors and determine information to be transmitted to a global computer system that is part of the system for condition-based maintenance, the central computer system being configured to further transmit only information that may be of interest to other storage and retrieval systems; The global computer system is configured to receive the condition-based information from the central computer system and determine trends related to component inspections or component changes, and the global computer system communicates information about the trends to inspection scheduling managers of individual central computer systems.

2. 2. The system of claim 1, wherein the at least one container handling vehicle (201, 301, 401) has at least one rechargeable power source (405), and the system has at least one charging device for charging the rechargeable power source of the container handling vehicle (201, 301, 401).

3. 10. The system of claim 1, comprising a global computer system configured to collect and analyze information from the central computer system of each individual storage and retrieval system, production and testing facilities, and inspection vendors, and return relevant information to the central computer system of each individual storage and retrieval system.

4. The system of claim 3 , wherein the sensor (501) comprises a temperature sensor and / or a humidity sensor.

5. 5. The system of claim 1, 3, or 4, wherein the inspection center (502) is configured to record and store a data record when a component fails, the data record comprising information related to the component, its inspection time, and / or age.

6. A system as described in any one of claims 1 to 5, wherein a container handling vehicle (201, 301, 401) with a worn component is instructed by the central computer system to adapt its speed, acceleration, and deceleration to suit the condition of the worn component.

7. The system of any one of claims 1 to 6, wherein the container handling platform of the container handling vehicle (201, 301) has a sensor (501) that detects when a storage container (106) encounters resistance or becomes stuck within a storage container column of the storage and retrieval system (1).

8. 1. A method for condition-based maintenance of an automated storage and retrieval system, comprising: The system comprises: a skeletal structure (100) with a rail system, said skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items; the grid structure (104) forms vertical storage columns (105), each of the vertical storage columns (105) having a horizontal area defined by the size of an access opening (112) between the rails of the rail system (108) disposed on the framework structure (100); the rail system (108) provides an available path for container handling vehicles (201) to handle the storage containers (106) and transport the storage containers (106) to and from the vertical storage columns (105); a skeletal structure (100); at least one container handling vehicle (201, 301), said at least one container handling vehicle (201, 301) having a container handling platform (500) with a set of grippers for handling said storage containers (106); The grid structure includes one or more ports for extracting containers (106) from the storage grid so that they can be loaded. at least one container handling vehicle (201, 301); an inspection station (502) for performing maintenance on components of said storage and retrieval system (1); Equipped with The method comprises: - collecting information from sensors (601) monitoring components of said storage and retrieval system (1); - monitoring the condition of the components of said storage and retrieval system; - transmitting information about the condition of said components of said storage and retrieval system to a central computer system; - transmitting from said central computer system (503) to a global computer system (507) only information that may be of interest to other storage and retrieval systems; - analyzing said information regarding the condition of said components of said storage and retrieval system using an inspection schedule manager (506); - generating an inspection action plan based on the analyzed information regarding the condition of the components of the storage and retrieval system; - transmitting said inspection execution plan to at least one inspection station (502); - performing condition-based maintenance when required; - determining, by the global computer system, trends regarding component inspections or changes based on information from the central computer system; - transmitting, by the global computer system, information about said trends to inspection schedule managers of individual central computer systems to update information about said inspection schedules; A method comprising:

9. 9. The method of claim 8, wherein the information from the sensors comprises a record of problems with the components of the storage and retrieval system along with information regarding their service time and age.

10. The method of claim 8 or 9, wherein the method includes allocating container handling vehicles (201, 301, 401) having worn components to less demanding tasks on a task list.

11. A method according to any one of claims 8 to 10, wherein the method comprises adapting the speed, acceleration and deceleration of a container handling vehicle (201, 301, 401) with a worn component to suit the condition of the worn component.

12. The method according to any one of claims 8 to 11, comprising mounting a sensor (501) on a gripper element of a container handling platform of a container handling vehicle (201, 301), the sensor (501) detecting when a storage container (106) is stuck within a storage container column of the storage and retrieval system (1).

13. The method of any one of claims 8-12, wherein the method includes updating (608) information from production and test facilities (504) and transmitting the updated information to the central computer system (503).

14. The method of any one of claims 8-13, wherein the method includes updating (609) information from a service provider and transmitting the updated information to the central computer system (503).

Images