System and method for detecting anomalies in trucks on a three-dimensional storage system

Abstract

A system (600) and method for condition-based maintenance of an automated storage and retrieval system comprising a skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items, wherein a rail system (108) is arranged on the skeletal structure (100) to provide available routes for container handling vehicles (201) that handle the storage containers and transfer the storage containers (106) to and from storage columns (105). The system (600) and method comprises at least one container handling vehicle having at least two sensors set up to report the condition of the rails of the rail system (108).

Description

[Technical Field]

[0001] The present invention relates to a system and method for condition-based monitoring of an automated storage and retrieval system, and more particularly to a system and method for condition-based monitoring of an automated storage and retrieval system for detecting anomalies within a three-dimensional storage system. [Background technology]

[0002] BACKGROUND AND PRIOR ART 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 side by side between the upright members 102 and the horizontal members 103. In these storage columns 105, storage containers 106, also known as receptacles, are stacked on top of each other to form stacks 107. The members 102, 103 may typically be made from metal, for example, extruded aluminum profiles.

[0004] The framework structure 100 of the automated storage and retrieval system 1 comprises a rail system 108 arranged across the top of the framework structure 100, on which a plurality of container handling vehicles 201, 301 are operated to lift storage containers 106 from, lower storage containers 106 into, and transport storage containers 106 up the storage columns 105. The rail system 108 comprises a first set of parallel rails 110 arranged 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 arranged 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, ie in a plane that is parallel to the horizontal XY plane.

[0005] The uprights 102 of the skeletal structure 100 may be used to guide the storage containers during lifting out of and lowering into the column 105. The stack 107 of containers 106 is typically freestanding.

[0006] Each prior art container handling vehicle 201, 301 comprises a carbody 201a, 301a and first and second sets of wheels 201b, 301b, 201c, 301c that respectively enable lateral movement of the container handling vehicle 201, 301 in the X and Y directions. Two wheels in each set are fully visible in Figures 2 and 3. The first set of wheels 201b, 301b are arranged to engage two adjacent rails of the first set of rails 110, and the second set of wheels 201c, 301c are arranged 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 the storage containers 106 into the storage columns 105). The lifting device includes one or more gripping / engaging devices adapted to engage the storage containers 106, and the gripping / engaging devices can be lowered from the vehicle 201, 301 such that the position of the gripping / engaging devices relative to the vehicle 201, 301 can be adjusted in a third direction Z that 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 by reference numeral 304. The gripping device of the container handling device 201 is located within the vehicle body 301a in FIG. 2.

[0008] As before, and 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, and so on. 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. Thus, as an example, using the Cartesian coordinate system X, Y, Z shown in FIG. 1, the 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. As shown in FIG. 2 and described, for example, in WO 2015 / 193278 A1 (Patent Document 1), the contents of which are incorporated herein by reference, the storage space may include a cavity centrally arranged within the vehicle body 201 a.

[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, as disclosed, for example, in WO2014 / 090684A1 (Patent Document 2).

[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 3), the contents of which are incorporated herein by reference, illustrates a typical configuration of a rail system 108 with rails and parallel tracks in both the X and Y directions.

[0016] In the skeleton structure 100, most 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 dedicated 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 the storage containers 106 can be accessed from outside the skeleton structure 100 or transferred out of or into the skeleton structure 100. In the art, such locations are typically referred to as "ports," and the columns in which the ports are located can be referred to as "port columns" 119, 120. Transport to the access stations can be horizontal, diagonal, and / or vertical. For example, storage containers 106 may be installed in random or dedicated columns 105 within the skeletal 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 a general transport orientation somewhere between horizontal and vertical.

[0017] In FIG. 1, the first port column 119 may be, for example, a dedicated loading 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 that have been transported from an access or transfer station.

[0018] An access station may typically be a picking or stocking station where product items are removed from or placed into storage containers 106. At a picking or stocking 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. Ports can also be used to transfer storage containers to another storage facility (e.g., another backbone structure, or another automated storage and retrieval system), a transport vehicle (e.g., a train or lorry), or a production facility.

[0019] A conveyor system comprising conveyors is typically employed to transport storage containers between the port columns 119, 120 and the access stations.

[0020] 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.

[0021] The conveyor system may be arranged to transport storage containers 106 between different skeletal structures, for example as described in WO2014 / 075937A1 (Patent Document 4), the contents of which are incorporated herein by reference.

[0022] 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 loading 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 loading 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 above-positioned storage container prior to raising the target storage container 106 from the storage column 105. This step, sometimes referred to in the art as "digging," may then be performed using the same container handling vehicle used to transport the target storage container to the loading port column 119, or may be performed using one or more other cooperating container handling vehicles. Alternatively, or in addition, the automated storage and retrieval system 1 may have container handling vehicles 201, 301 specifically dedicated to the task of temporarily removing the storage container 106 from the storage column 105. Once the target storage container 106 is removed from the storage column 105, the temporarily removed storage container 106 can be repositioned in the original storage column 105. However, the removed storage container 106 may alternatively be relocated to another storage column 105.

[0023] 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 container 106 located at or above the target location in the stack 107 is removed, the container handling vehicle 201, 301 positions the storage container 106 in the desired location. The removed storage container 106 may then be lowered back into the storage column 105 or may be relocated to another storage column 105.

[0024] To monitor and control the automated storage and retrieval system 1 (e.g., 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 includes a control system 500, which is typically computerized and typically includes a database for tracking the storage containers 106.

[0025] A problem with storage grids is that over time, dirt and dust collect inside the tracks that container handling vehicles drive over them. This can damage the vehicles, leading to added expense and risk. Additionally, the tracks, as well as the framework of the underlying storage units, can suffer wear and tear over time. Currently, there is no method for scouting for possible failures. Robots must stop due to errors across the problem area for the problem to be detected. This is a costly and time-consuming method of addressing the problem.

[0026] Another problem with this situation is that there is no easy way to inspect the legs of the storage facility. If there are alignment issues with the column, this can lead to the gripper, with or without containers, colliding with the column on the way up or down, which over time will damage the equipment. This will require the storage facility to be shut down, which again is costly and time consuming. [Prior art documents] [Patent documents]

[0027] [Patent Document 1] International Publication No. 2015 / 193278 [Patent Document 2] International Publication No. 2014 / 090684 [Patent Document 3] International Publication No. 2018 / 146304 [Patent Document 4] International Publication No. 2014 / 075937 Summary of the Invention [Means for solving the problem]

[0028] (Summary of the Invention) The present invention is set forth and characterized in the independent claims, while the dependent claims describe further characteristics of the invention.

[0029] In one aspect, the present invention relates to a system for condition-based monitoring of an automated storage and retrieval system comprising a skeletal structure 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 in the vertical storage column, the skeletal structure comprising a rail system arranged above the storage columns, the rail system comprising a plurality of rails extending in an X direction and a Y direction to form the grid, the rails defining a perimeter of each access opening at the top of each storage column, the rail system being operable to handle the storage containers, transport the storage containers into the storage columns, and transport the storage containers from the storage columns. and providing available routes in X and Y directions for container handling vehicles to transfer containers from and to the container handling vehicle, at least one container handling vehicle having two or more sensors oriented to monitor sections of rail adjacent to the container handling vehicle, the sensors being part of a monitoring system set up to report rail conditions of the grid system and upload information to one or all of a central computer system, a cloud system, and / or an image analysis and processing system, the two or more sensors being at least one camera and a pendulum and / or a spirit level and / or an accelerometer and / or a sound detection device.

[0030] Further, the at least one sensor may be a camera that may be mounted on the side of the container handling vehicle in the direction of travel of the container handling vehicle so as to be oriented to observe an area of ​​the rail system that is at a level below the height of the at least one camera on the container handling vehicle.

[0031] The container handling vehicle may also have cameras on all sides of the container handling vehicle oriented to observe areas of the rail system that are at a level below the height of at least one camera on the container handling vehicle.

[0032] Additionally, the central computer system, cloud storage, and / or image analysis and processing system may be configured to process information gathered by the at least one sensor.

[0033] At least one camera on each side of the container handling vehicle in the direction of travel of the container handling vehicle may be aimed at an angle of between 0° and 89° pointing downward from horizontal level.

[0034] At least one camera of the container handling vehicle may be mounted on top of the container handling vehicle and oriented at an angle of 0° to 89° pointing downward from horizontal level.

[0035] The at least one sensor may be in the form of a pendulum and / or a spirit level and / or an accelerometer and / or a sound detection device.

[0036] At least one sensor may be mounted on a lift platform of the container handling vehicle.

[0037] There may be at least one sensor connected to each of the wheels on the container handling vehicle.

[0038] At least one sensor may be an accelerometer that detects whether the wheels are turning.

[0039] The container handling vehicle may have sensors to monitor the tilt and movement of the vehicle.

[0040] The at least one sensor may be a sound detection device on the lifting platform to detect whether the container handling vehicle hits an obstacle in the cell during the raising and lowering of the container into the cell of the storage system.

[0041] At least one camera may be mounted on a lift platform of the container handling vehicle.

[0042] In a second aspect, the present invention relates to a method for condition-based maintenance of an automated storage and retrieval system comprising a skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items, the grid structure (104) forming vertical storage columns (105), each having a horizontal area defined by the size of an access opening (112) in the vertical storage column (105), the skeletal structure comprising a rail system (108) arranged on the storage columns (105), the rail system comprising a plurality of rails extending in the X and Y directions to form a grid, the rails defining the perimeter of each access opening (112) at the top of each storage column (105), and the rail system (108) supporting a container handling vehicle (201) for handling the storage containers (106) and transporting the storage containers (106) to and from the storage columns (105) in the X and Y directions. and providing available routes for the rails, the method comprising the following steps: moving a container handling vehicle from one vertical storage column to another in a storage grid; taking images of an area of ​​the rails, the area including the vertical storage columns; using a pendulum, and / or a spirit level, and / or an accelerometer, and / or a sound detection device connected to the container handling vehicle to gather additional information about the rails on the grid; uploading the images to one or all of a central computer system, a cloud system, and / or an image analysis and processing system; detecting anomalies in the tracks on the grid; and the central computer system, the cloud system, and / or the image analysis and processing system issuing recommendations on where to inspect and / or clean the storage grid based on an analysis of the storage system.

[0043] Taking the images may include taking images looking straight down along the side of the container handling vehicle as the vehicle rests above the vertical storage column.

[0044] Taking the images may include taking images of a storage grid to each side of the container handling vehicle while the container handling vehicle is stationary above the vertical storage column.

[0045] Capturing the image may include using a camera mounted at an angle of 0° to 89° pointing downward from horizontal.

[0046] Detecting anomalies in tracks on a grid may involve using machine learning to analyze uploaded images.

[0047] Taking the images may include using at least one additional camera mounted on a lift platform of the container handling vehicle.

[0048] Also, using machine learning to analyze the uploaded images and detect anomalies in trucks on the grid includes using at least one additional camera mounted on a lift platform of the container handling vehicle.

[0049] The use of the invention as set out in the set of claims solves the above mentioned problems. The present invention provides, for example, the following. (Item 1) A system for condition-based monitoring of an automated storage and retrieval system comprising a skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items, said grid structure (104) forming vertical storage columns (105) each having a horizontal area defined by the size of an access opening (112) in said vertical storage column (105), said skeletal structure comprising a rail system (108) arranged above said storage columns (105), said rail system comprising a plurality of rails extending in an X direction and a Y direction to form a grid, said rails (100) defining the perimeter of each access opening (112) at the top of each storage column (105), said rail system (108) handling storage containers (106) and transporting storage containers (106) to said storage columns (105). and providing available routes in X and Y directions for container handling vehicles (201, 301) that transport containers to and from the storage columns (105), wherein at least one container handling vehicle has two or more sensors oriented to monitor the section of the rail adjacent to the container handling vehicle, the sensors being part of a monitoring system set up to report the status of the rails of the grid system and upload information to one or all of a central computer system, a cloud system, and / or an image analysis and processing system, wherein the two or more sensors are at least one camera, a pendulum and / or a spirit level and / or an accelerometer and / or a sound detection device. (Item 2) The system described in item 1, wherein the at least one sensor is a camera mounted on the side of the container handling vehicle in the direction of travel of the container handling vehicle so as to be oriented to observe an area of ​​the rail system that is at a level below the height of the at least one camera on the container handling vehicle. (Item 3) The system described in item 1, wherein the container handling vehicle may have cameras on all sides of the container handling vehicle oriented to observe areas of the rail system that are at a level below the height of the at least one camera on the container handling vehicle. (Item 4) 10. The system of claim 1, wherein the central computer system, cloud storage, and / or image analysis and processing system are configured to process the information gathered by the at least one sensor. (Item 5) A system as described in any of the preceding items, wherein the at least one camera on each side of the container handling vehicle in the direction of travel of the container handling vehicle is at an angle of 0° to 89° pointing downward from horizontal. (Item 6) The system described in any of the preceding items, wherein the at least one camera of the container handling vehicle is mounted on top of the container handling vehicle at an angle of 0° to 89° pointing downward from horizontal level. (Item 7) Item 10. The system of item 1, wherein the at least one sensor is mounted on a lift platform of the container handling vehicle. (Item 8) Item 10. The system of item 1, wherein there is at least one sensor connected to each of the wheels on the container handling vehicle. (Item 9) Item 10. The system of item 1, wherein the at least one sensor is an accelerometer that detects whether the wheel is turning. (Item 10) Item 10. The system of item 9, wherein the container handling vehicle has sensors for monitoring tilt and movement of the vehicle. (Item 11) Item 11. The system of item 10, wherein the at least one sensor is a sound detection device on the lifting platform for detecting whether the container handling vehicle hits an obstacle in a cell during the raising and lowering of a container into the cell of the storage system. (Item 12) 10. The system of claim 1, wherein at least one camera is mounted on the lift platform of the container handling vehicle. (Item 13) 1. A method for condition-based maintenance of an automated storage and retrieval system comprising a skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items, said grid structure (104) forming vertical storage columns (105) each having a horizontal area defined by the size of an access opening (112) in said vertical storage columns (105), said skeletal structure comprising a rail system (108) arranged on said storage columns (105), said rail system comprising: , a plurality of rails extending in the X and Y directions to form a grid, the rails defining the periphery of each access opening (112) at the top of each storage column (105), the rail system (108) providing available routes for container handling vehicles (201) to handle storage containers (106) and transfer the storage containers (106) to and from the storage columns (105) in the X and Y directions, the method comprising the steps of: - moving a container handling vehicle from one vertical storage column to another vertical storage column within said storage grid; - taking an image of an area of ​​the rail, the area including vertical storage columns; - using a pendulum, and / or a spirit level, and / or an accelerometer, and / or a sound detection device connected to the container handling vehicle to gather additional information about rails on the grid; - uploading the images to one or all of a central computer system, a cloud system, and / or an image analysis and processing system; - detecting anomalies in tracks on the grid; - a central computer system, a cloud system, and / or an image analysis and processing system issuing recommendations on where to inspect and / or clean the storage grid based on the analysis of the storage system; A method comprising: (Item 14) 14. The method of claim 13, wherein taking an image includes taking an image directly down along the side of the container handling vehicle while the vehicle is stationary above a vertical storage column. (Item 15) 15. The method of claim 13, wherein taking images includes taking images of the storage grid on each side of the container handling vehicle while the container handling vehicle is stationary above a vertical storage column. (Item 16) 16. The method of any one of items 13 to 15, wherein capturing the image includes using a camera mounted at an angle of 0° to 89° pointing downward from horizontal. (Item 17) 17. The method of claim 13, wherein detecting anomalies in the tracks on the grid includes using machine learning to analyze the uploaded images. (Item 18) 17. The method according to any one of items 13 to 16, wherein taking an image includes using at least one additional camera mounted on the lift platform of the container handling vehicle. [Brief explanation of the drawings]

[0050] BRIEF DESCRIPTION OF THE DRAWINGS The following drawings are included to facilitate an understanding of the invention: The drawings illustrate embodiments of the invention, which are described herein by way of example only.

[0051] [Figure 1]FIG. 1 is a perspective view of the skeletal structure of a prior art automated storage and retrieval system.

[0052] [Figure 2] FIG. 2 is a perspective view of a prior art container handling vehicle having a centrally arranged cavity for holding storage containers therein.

[0053] [Figure 3] FIG. 3 is a perspective view of a prior art container handling vehicle having a cantilever for holding a storage container underneath.

[0054] [Figure 4] FIG. 4 is a side view of a prior art container handling vehicle, where containers can be stored on top of the vehicle.

[0055] [Figure 5a] FIG. 5a is a side view of an embodiment of the present invention in which a container handling vehicle with a center cavity solution has a camera mounted on the side of the vehicle facing downwards.

[0056] [Figure 5b] FIG. 5b is a side view of an embodiment of the present invention in which a container handling vehicle with a center cavity solution has a camera mounted on the side of the vehicle facing outwards.

[0057] [Figure 6] FIG. 6 is a perspective view of a container handling vehicle with a central cavity solution, in which several sets of wheels of the container handling vehicle have a pendulum function.

[0058] [Figure 7a] FIG. 7a is a side view of an embodiment of the present invention of a container handling vehicle with a cantilever solution with a downward facing camera.

[0059] [Figure 7b]FIG. 7b is a side view of an embodiment of the present invention of a container handling vehicle with a cantilever solution with an outward facing camera.

[0060] [Figure 8a] FIG. 8a is a side view of an embodiment of the present invention, where the container handling vehicle involves a cantilever solution, where the lifting platform has an outward facing camera mounted on it.

[0061] [Figure 8b] FIG. 8b is a side view of an embodiment of the present invention in which a container handling vehicle with a cantilever solution has a camera mounted on a lifting platform facing downwards.

[0062] [Figure 9a] FIG. 9a is a side view of an embodiment of the present invention in which a container handling vehicle with a topside holding solution has a side-mounted camera facing downwards.

[0063] [Figure 9b] FIG. 9b is a side view of an embodiment of the present invention in which a container handling vehicle with a topside holding solution has a side-mounted camera facing outwards.

[0064] [Figure 10a] FIG. 10a is a side view of an embodiment of the present invention in which a container handling vehicle with a center cavity solution has a top mounted camera.

[0065] [Figure 10b] FIG. 10b is a side view of an embodiment of the present invention where a container handling vehicle with a cantilever solution has a top mounted camera. DETAILED DESCRIPTION OF THE INVENTION

[0066] Detailed Description of the Drawings In the following, embodiments of the present invention will be discussed in more detail with reference to the accompanying drawings, although it should be understood that the drawings are not intended to limit the invention to the subject matter depicted in the drawings.

[0067] According to a preferred embodiment of the present invention, monitoring the status of the storage and retrieval system may be accomplished by at least one container handling vehicle that travels from column to column and takes measurements.

[0068] In an alternative embodiment of the present invention, a container handling vehicle operating on the storage and retrieval system may monitor the status of the storage and retrieval system during operation.

[0069] In yet another embodiment of the invention, at least one container handling vehicle may travel from column to column and take measurements at fixed intervals to detect loose framework or broken grid legs, or any other measurements that may not be taken during normal operation. Inspection of dirt, dust, or debris within the tracks on the storage and retrieval system may be performed by the container handling vehicle during normal operation.

[0070] The skeleton structure 100 of the automated storage and retrieval system 1 is constructed in accordance with the prior art skeleton structure 100 described above in connection with FIG. 1, i.e., several upright members 102 and several horizontal members 103 supported by the upright members 102, and the skeleton structure 100 further comprises a first upper rail system 108 in the X and Y directions.

[0071] The skeleton structure 100 further comprises storage compartments in the form of storage columns 105 provided between the members 102, 103, with storage containers 106 being stackable in stacks 107 within the storage columns 105.

[0072] Skeleton structure 100 can be of any size. In particular, it should be understood that the skeletal structure can be significantly wider and / or longer and / or deeper than that disclosed in Figure 1. For example, skeletal structure 100 may have a horizontal extent of greater than 700 x 700 columns and a storage depth of greater than 12 containers.

[0073] FIG. 1 is a perspective view of the skeletal structure of a prior art automated storage and retrieval system.

[0074] Figures 2, 3 and 4 are perspective views of a prior art container handling vehicle having a centrally arranged cavity for holding storage containers therein and a cantilever solution for holding storage containers underneath the container handling vehicle.

[0075] FIG. 5a is a side view of an embodiment of the present invention in which a container handling vehicle with a center cavity solution has a camera mounted on the side of the vehicle, the camera facing downwards.

[0076] There are cameras mounted on each side of the container handling vehicles. Each camera faces downwards to capture an image of the trucks that make up the framework of the column or columns above which the container handling vehicles are positioned. This solution gives the closest possible image of the truck, so it is possible to ascertain whether there is anything present in the truck and, optionally, what that object is. If it is known what the object on the truck actually is, it is much easier to ascertain whether this is something that requires immediate attention, or whether it can be dealt with later at a slower time of the day, when repairs can be made without the entire storage and retrieval system having to be shut down.

[0077] FIG. 5b is a side view of an embodiment of the present invention in which a container handling vehicle with a center cavity solution has a camera mounted on the side of the vehicle facing outwards.

[0078] In this solution, there is a camera on each side of the container handling vehicle. The cameras are angled downwards. The angle at which the cameras are angled can be from 0° to 89° downwards from the horizon, meaning from directly below to nearly horizontal.

[0079] In a further solution, the cameras can be movable, allowing one camera on each side to cover 180° from directly below to directly above. This solution allows one container handling vehicle to obtain several images from each side of the container handling vehicle. There are several advantages to this solution. It allows a central computer system, or a cloud service, or an image analysis and processing system to obtain more images of each column. This allows analysis tools to determine which movements of the framework, tracks, or grid are due to the load of the container handling vehicle. Therefore, if it is possible to obtain several images from different angles and different sides, with and without load on the tracks directly above the column, it is easier to determine what the situation actually is.

[0080] Figure 6 is a perspective view of a container handling vehicle with a central cavity solution, where several pairs of wheels on the container handling vehicle have a pendulum function. The pendulum function allows two pairs of wheels to move at an angle. This adds instrumentation to the robot's pendulum, and if the robot's pendulum reaches its maximum angle, there is a risk that the cell's irregularities are higher than the robot can overcome, with the potential for a collision.

[0081] Another approach to detecting track irregularities is to add at least one electronic level, which indicates the angle at which the track is off-line and whether this is something that, for example, a container handling vehicle's pendulum can overcome, or something that requires immediate attention and locks down part or all of the storage and retrieval system.

[0082] FIG. 7a is a side view of an embodiment of the present invention of a container handling vehicle with a cantilever solution with a downward facing camera.

[0083] There are cameras mounted on each side of the container handling vehicles. Each camera faces downwards to capture an image of the trucks that make up the framework of the column or columns above which the container handling vehicles are positioned. This solution gives the closest possible image of the truck, so it is possible to ascertain whether there is anything present in the truck and, optionally, what that object is. If it is known what the object on the truck actually is, it is much easier to ascertain whether this is something that requires immediate attention, or whether it can be dealt with later at a slower time of the day, when repairs can be made without the entire storage and retrieval system having to be shut down.

[0084] FIG. 7b is a side view of an embodiment of the present invention of a container handling vehicle with a cantilever solution with an outward facing camera.

[0085] In this solution, a camera is present on each side of the container handling vehicle. The cameras are angled downwards. The angle at which the cameras are angled can be between 0° and 89° downwards from the horizon.

[0086] In a further solution, the cameras can be moved to cover 180° from directly below to directly above with one camera on each side. This solution allows one container handling vehicle to obtain several images from each side of the container handling vehicle. There are several advantages to this solution. It allows a central computer system, or a cloud service, or an image analysis and processing system to obtain more images of each column. This allows analysis tools to determine which movements of the framework, tracks, or grid are due to the load of the container handling vehicle. Therefore, if it is possible to obtain several images from different angles and different sides, with and without load on the tracks directly above the column, it is easier to determine what the situation actually is.

[0087] FIG. 8a is a side view of an embodiment of the present invention, where the container handling vehicle involves a cantilever solution, where the lifting platform has an outward facing camera mounted on it.

[0088] On all sides there are cameras facing outwards, which allows the invention to take images as the lift platform of the container handling vehicle is lowered into the column. With this solution it is even possible to take images of the grid legs by lowering the lift platform all the way into the column. Furthermore, lighting can be present on the lift frame, as it can be dark below the column.

[0089] It is also possible to use types of equipment other than cameras to inspect the condition below the column. One such example would be Lidar, which is an excellent way to inspect the height position and skeletal level of the trucks from below.

[0090] FIG. 8b is a side view of an embodiment of the present invention in which a container handling vehicle with a cantilever solution has a camera mounted on a lifting platform facing downwards.

[0091] There is one camera that can be moved around covering the entire area below the lift platform. This allows the invention to take images as the lift platform of the container handling vehicle is lowered into the column. With this solution it is even possible to take images of the grid legs by lowering the lift platform all the way into the column. Furthermore, lighting can be present on the lift frame, as it can be dark below the column.

[0092] It is also possible to use types of equipment other than cameras to inspect the condition below the column. One such example would be a lidar, which is an excellent way to inspect the track height and skeletal level below.

[0093] Although the drawings in Figures 8a and 8b show a container handling vehicle with a cantilever solution, the present technical feature which involves mounting one or more cameras on the lifting platform of the container handling vehicle can be applied just as well as when applied to a central cavity solution.

[0094] FIG. 9a is a side view of an embodiment of the present invention in which a container handling vehicle with a topside holding solution has a side-mounted camera facing downwards.

[0095] There are cameras mounted on each side of the container handling vehicles. Each camera faces downwards to capture an image of the trucks that make up the framework of the column or columns above which the container handling vehicles are positioned. This solution gives the closest possible image of the truck, so it is possible to ascertain whether there is anything present in the truck and, optionally, what that object is. If it is known what the object on the truck actually is, it is much easier to ascertain whether this is something that requires immediate attention, or whether it can be dealt with later at a slower time of the day, when repairs can be made without the entire storage and retrieval system having to be shut down.

[0096] FIG. 9b is a side view of an embodiment of the present invention in which a container handling vehicle with a topside holding solution has a side-mounted camera facing outwards.

[0097] In this solution, a camera is located on each side of the container handling vehicle. The cameras are angled downwards. The angle at which the cameras are angled can be between 0° and 89° downwards from the horizon.

[0098] In a further solution, the cameras can be moved to cover 180° from directly below to directly above with one camera on each side. This solution allows one container handling vehicle to obtain several images from each side of the container handling vehicle. There are several advantages to this solution. It allows a central computer system, or a cloud service, or an image analysis and processing system to obtain more images of each column. This allows analysis tools to determine which movements of the framework, tracks, or grid are due to the load of the container handling vehicle. Therefore, if it is possible to obtain several images from different angles and different sides, with and without load on the tracks directly above the column, it is easier to determine what the situation actually is.

[0099] FIG. 10a is a side view of an embodiment of the present invention in which a container handling vehicle with a central cavity solution has a top-mounted camera. This camera can capture images in all directions by moving the camera around. Therefore, it is a consideration of whether the additional investment in terms of the number of cameras is worthwhile or whether it is more expensive to shut down the storage and retrieval system for a longer period of time. FIG. 10b is a side view of an embodiment of the present invention in which a container handling vehicle with a cantilever solution has a top-mounted camera. This is the same technical feature as presented in FIG. 10a, except that a top-mounted camera is mounted on a container handling vehicle with a cantilever solution instead of a central cavity solution.

[0100] An additional sensor used to detect irregularities in the framework of the storage and retrieval system is a motion sensor. The motion sensor can detect motion in any direction. Motion is an indication that the tracks or framework of the storage and retrieval system are not normal, and the collected information can be sent to a central computer system, cloud service, or image analysis and processing system to analyze where the problem exists within the storage and retrieval system. The motion sensor can provide information that an image cannot, such as if there is a portion of the grid that yields when there is a load on it. If the framework yields when a container handling vehicle drives over it, the motion sensor can provide information such as how much it yields and in what direction. With this stored information, it is possible to find where the problem may be in the framework.

[0101] During analysis, there is an advantage when having measurements of neighboring columns, which allows the analysis program to obtain information regarding the extent and location of the problem. Thus, in a preferred solution of the present invention, if a problem with one of the columns is identified as present, images and measurements of neighboring columns can be used along with information from that column to obtain an estimate regarding the extent of the problem, such as whether the problem is a recent occurrence or whether it has gradually worsened over time.

[0102] Adding a sound detection device in the container handling vehicle's grabber allows for detection of whether the container handling vehicle hits an obstacle in the cell during the lifting and lowering of a container into the storage system's cell. The sound recorder can separate unwanted noise from the background noise of the container handling vehicle's operation.

[0103] Cameras, lidar, sound and all other types of sensors can be fitted into containers that can be grasped by the lifting platform of the container handling vehicle or can be installed on top of the container handling vehicle according to FIG.

[0104] Container handling vehicles may also be equipped with accelerometers to detect if the wheels are slipping on the tracks.

[0105] In the foregoing 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, as well as 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.

[0106] Reference Number List [Table 1-1] Table 1-2

Claims

1. 1. A monitoring system for condition-based monitoring of an automated storage and retrieval system comprising a skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items, said storage grid structure (104) forming vertical storage columns (105), each vertical storage column (105) having a horizontal area defined by the size of an access opening (112) in said vertical storage column (105), said skeletal structure being arranged above said vertical storage columns (105). The storage system (105) comprises a rail system (108) having a plurality of rails extending in the X and Y directions, the rails defining the periphery of each access opening (112) at the top of each vertical storage column (105), and the rail system (108) is connected to container handling vehicles (201, 30) that handle the storage containers (106), transfer the storage containers (106) to the vertical storage columns (105), and transfer the storage containers (106) from the vertical storage columns (105). 1) provides available routes in the X direction and / or the Y direction for the container handling vehicle (106), the monitoring system comprising at least one container handling vehicle and two or more sensors, the sensors (i) being included within the at least one container handling vehicle (201, 301) or (ii) being fitted to a container (106) that is graspable by a lift platform of the container handling vehicle or that can be mounted on top of the at least one container handling vehicle (201, 301), the sensors being oriented to monitor a section of the rail adjacent to the container handling vehicle, the monitoring system being arranged to report a condition of the rail and upload information to one or all of a central computer system, a cloud storage system, and / or an image analysis and processing system, the two or more sensors comprising at least one camera, a pendulum, and / or a spirit level, and / or an accelerometer, and / or a sound detection device.

2. 2. The monitoring system of claim 1, wherein the sensor comprises a camera mounted on a side of the container handling vehicle in the direction of travel of the container handling vehicle so as to be oriented to observe an area of ​​the rail system that is at a level below the height of the at least one camera on the container handling vehicle.

3. 2. The surveillance system of claim 1, wherein the container handling vehicle has cameras on all sides of the container handling vehicle, each camera oriented to observe an area of ​​the rail system that is at a level below the height of the respective camera on the container handling vehicle.

4. The surveillance system of any one of claims 1 to 3, wherein the central computer system, the cloud storage system, and / or the image analysis and processing system are configured to process the information collected by the sensors.

5. 4. The surveillance system of claim 3, wherein each camera on each side of the container handling vehicle in each direction of travel of the container handling vehicle is at an angle of 0° to 89° pointing downward from horizontal.

6. 4. The surveillance system of claim 3, wherein each camera on the container handling vehicle is mounted on top of the container handling vehicle at an angle of 0° to 89° pointing downward from the horizontal.

7. The monitoring system of claim 1 , wherein the sensor is mounted on a lift platform of the container handling vehicle.

8. 10. The monitoring system of claim 1, wherein there is at least one sensor connected to each of the wheels on the container handling vehicle.

9. The monitoring system of claim 8 , wherein the at least one sensor is an accelerometer that detects whether the wheels are turning.

10. 10. The monitoring system of claim 1, wherein the container handling vehicle has sensors for monitoring tilt and movement of the vehicle.

11. 2. The monitoring system of claim 1, wherein the sensor comprises a sound detection device on the lifting platform for detecting whether the container handling vehicle hits an obstacle within a cell during the raising and lowering of a container into the cell of the automated storage and retrieval system.

12. The surveillance system of claim 1 , wherein at least one camera is mounted on the lift platform of the container handling vehicle.

13. A method for condition-based maintenance of an automated storage and retrieval system comprising a skeletal structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items, said storage grid structure (104) forming vertical storage columns (105), each vertical storage column (105) having a horizontal area defined by the size of an access opening (112) in said vertical storage column (105), said skeletal structure comprising a rail system (108) arranged on said vertical storage columns (105), said rail system extending in an X-direction and a Y-direction. a plurality of rails located on a top surface of the vertical storage column (105), the rails defining the periphery of each access opening (112) at the top of each vertical storage column (105), the rail system (108) providing available routes for container handling vehicles (201) to handle the storage containers (106) and to transfer the storage containers (106) to and from the vertical storage columns (105) in the X and / or Y directions, the method comprising the steps of: - moving a container handling vehicle from one vertical storage column to another vertical storage column within said storage grid structure; - taking an image of an area of ​​the rail, said area including vertical storage columns; - using a pendulum, and / or a spirit level, and / or an accelerometer, and / or a sound detection device connected to the container handling vehicle to gather additional information about the rail; uploading said images to one or all of a central computer system, a cloud system, and / or an image analysis and processing system; - detecting anomalies in the rail; a central computer system, a cloud system, and / or an image analysis and processing system issuing recommendations on where to inspect and / or clean the storage grid structure based on the detecting step; A method comprising:

14. 14. The method of claim 13, wherein taking images includes taking images directly down along the side of the container handling vehicle as the vehicle rests above a vertical storage column.

15. 15. The method of claim 13 or 14, wherein taking images includes taking images of the storage grid structure to each side of the container handling vehicle while the container handling vehicle is stationary above vertical storage columns.

16. 15. The method of claim 13 or 14, wherein capturing the image comprises using a camera mounted at an angle of between 0° and 89° pointing downward from the horizontal.

17. 15. The method of claim 13 or 14, wherein detecting anomalies in the rails on the storage grid structure includes using machine learning to analyze the uploaded images.

18. 15. A method according to claim 13 or 14, wherein taking images comprises using at least one additional camera mounted on a lift platform of the container handling vehicle.

Images