Grid Survey Module

Abstract

A method for measuring level deviations in an automated storage and retrieval system, the method comprising the steps of: positioning a container handling vehicle at a predetermined position on a grid; sending a data signal from a central control unit to the container handling vehicle instructing the container handling vehicle to move a predetermined distance in one direction (X, Y) along the grid; measuring at least one orientation parameter at predetermined intervals using an orientation sensor to generate orientation measurements indicative of the orientation of the container handling vehicle within a three-dimensional Cartesian coordinate reference system; sending data relating to the orientation measurements to the central control unit; and processing the orientation measurements using the central control unit to identify portions of the rail system that deviate from a predetermined value.

Description

Technical Field

[0001] Field of the Invention The present invention relates to an automatic storage and retrieval system for the storage and retrieval of containers, and particularly to a method for measuring level deviation in the columns of a grid.

Background Art

[0002] Background and Prior Art FIG. 1 discloses a typical prior art automatic storage and retrieval system 1 having 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 framework structure 100 includes a plurality of upright members 102 and a plurality of horizontal members 103 supported by the upright members 102. The members 102, 103 can typically be made from metal, such as extruded aluminum profiles.

[0004] The framework structure 100 defines a storage grid 104 including storage columns 105 arranged in columns, and the storage columns 105, also known as bins, contain storage containers 106 stacked on top of each other to form a stack 107. The storage grid 104 prevents horizontal movement of the stack 107 of storage containers 106 and guides vertical movement of the containers 106, but typically does not support the storage containers 106 when stacked.

[0005] The automated storage and retrieval system 1 includes a rail system 108 arranged in a grid pattern over the top of the storage section 104, on which multiple container handling vehicles 201, 301 are operated to raise storage containers 106 from storage columns 105, lower storage containers 106 into storage columns, and transport storage containers 106 onto storage columns 105. The rail system 108 includes a first pair of parallel rails 110 arranged to guide the movement of container handling vehicles 201, 301 in a first direction X traversing the top of the frame structure 100, and a second pair of parallel rails 111 arranged perpendicular to the first pair of rails 110 to guide the movement of container handling vehicles 201, 301 in a second direction Y perpendicular to the first direction X. In this way, the rail system 108 defines a grid column 112 above which container handling vehicles 201, 301 can move laterally above the storage column 105, i.e., in a plane parallel to the horizontal XY plane.

[0006] The control system 500 of the automatic storage and recovery system 1 communicates with vehicles 200 and 300.

[0007] Each of the conventional container handling vehicles 201, 301 comprises a body 201a, 301a and first and second sets of wheels 201b, 301b, 201c, 301c that enable lateral movement of the container handling vehicles 201, 301 in the X and Y directions, respectively. In Figures 2 and 3, the two wheels of each set are fully visible. The first set of wheels 201b, 301b are positioned to engage with two adjacent rails of the first set of rails 110, and the second set of wheels 201c, 301c are positioned to engage with two adjacent rails of the second set of rails 111. Each set of wheels 201b, 301b, 201c, and 301c can be raised and lowered, so that the wheels 201b, 301b of the first set and / or the wheels 201c, 301c of the second set can engage with their respective sets of rails 110, 111 at any given time.

[0008] Each of the conventional container handling vehicles 201, 301 also includes a lift device (not shown) for transporting a storage container 106 vertically, for example, raising the storage container 106 from a storage column and lowering the storage container 106 into a storage column 105. The lift device includes one or more gripping / engaging devices (not shown) adapted to engage with the storage container 106, and the gripping / engaging devices can be lowered from the vehicles 201, 301 so that the position of the gripping / engaging devices relative to the vehicles 201, 301 can be adjusted to a third direction Z perpendicular to a first direction X and a second direction Y.

[0009] Conventionally, and for the purposes of this application, Z=1 identifies the uppermost layer of grid 104, i.e., the layer directly below the rail system 108; Z=2 identifies the second layer below the rail system 108; and Z=3 identifies the third layer. In the exemplary prior art grid disclosed in Figure 1, Z=8 identifies the lowest layer of grid 104. Similarly, X=1...n and Y=1...n identify the position of each grid column 112 in the horizontal plane. Thus, using the Cartesian coordinate system X, Y, Z shown in Figure 1 as an example, it can be said that the storage container identified as 106' in Figure 1 occupies the grid position or cell X=10, Y=2, Z=3. The container handling vehicles 201, 301 can be said to be traveling in layer Z=0, and each grid column 112 can be identified by its X and Y coordinates.

[0010] Each of the conventional container handling vehicles 201, 301 is provided with a storage compartment or space for receiving and accommodating the storage container 106 when transporting the storage container 106 across the rail system 108. The storage space may include a centrally located cavity within the vehicle body 201a, as shown in Figure 2 and described, for example, in International Publication No. 2015 / 193278A1, the contents of which are incorporated herein by reference.

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

[0012] The central cavity container handling vehicle 201 shown in Figure 2 may have a footprint that covers the lateral range of grid column 112, i.e., an area having dimensions in the X and Y directions that are approximately equal to the range of grid column 112 in the X and Y directions, as described, for example, in International Publication No. 2015 / 193278A1, the contents of which are incorporated herein by reference. The term “lateral” as used herein may mean “horizontal.”

[0013] Alternatively, the central cavity container handling vehicle 101 may have a footprint larger than the lateral area defined by the grid columns 112, as disclosed, for example, in International Publication No. 2014 / 090684A1.

[0014] The rail system 108 may be a single-track rail system, as shown in Figure 4. Alternatively, the rail system 108 may be a double-track rail system, as shown in Figure 5, so that a container handling vehicle 201 having a footprint substantially corresponding to the lateral region defined by the grid column 112 can move along the row of grid columns, even if another container handling vehicle 201 is positioned above a grid column adjacent to its row. Both single and double-track rail systems, or combinations including single and double-track rail configurations within the rail system 108, form a grid pattern within a horizontal plane P containing a plurality of rectangular and uniform grid positions or grid cells 122, each grid cell 122 containing a grid opening 115 demarcated by a pair of tracks 110a, 110b of the first track 110 and a pair of tracks 111a, 111b of the second set of tracks 111. In Figure 5, the grid cells 122 are indicated by dashed boxes.

[0015] As a result, orbits 110a and 110b form a pair of orbits that define parallel rows of grid cells extending in the X direction, and orbits 111a and 111b form a pair of orbits that define parallel rows of grid cells extending in the Y direction.

[0016] As shown in Figure 6, each grid cell 122 has a width Wc typically ranging from 30 to 150 cm and a length Lc typically ranging from 50 to 200 cm. Each grid opening 115 has a width Wo and length Lo that are typically 2 to 10 cm smaller than the width Wc and length Lc of the grid cell 122.

[0017] In the X and Y directions, adjacent grid cells are arranged so that they touch each other without any gaps.

[0018] In the storage grid 104, the majority of the grid columns 112 are storage columns 105, i.e., grid columns 105 in which storage containers 106 are stored within the stack 107. However, the grid 104 typically has at least one grid column 112 that includes locations where container handling vehicles 201, 301 can drop off and / or pick up storage containers 106, not for storage purposes, and as a result they can be transported to access stations (not shown) in which storage containers 106 can be accessed from outside the grid 104 or transported outside or inside the grid 104. In the art, such locations are typically referred to as “ports,” and the grid column 112 in which a port is located may be referred to as a “port column” 119, 120. Transport to an access station may be in any direction, i.e., horizontal, inclined, and / or vertical. For example, the storage container 106 may be placed in a random or dedicated grid column 112 within the storage grid 104, and then picked up by any container handling vehicle and transported to ports 119, 120 for further transport to access stations. Note that the term “inclined” refers to the transport of the storage container 106 having a typical transport orientation somewhere between horizontal and vertical.

[0019] The grid 104 in Figure 1 comprises two port columns 119 and 120. The first port column 119 may be a dedicated drop-off port column from which container handling vehicles 201, 301 can drop off storage containers 106 being transported to an access or transfer station, for example, and the second port column 120 may be a dedicated pickup port column from which container handling vehicles 201, 301 can pick up storage containers 106 transported from an access or transfer station to the grid 104.

[0020] An access station is typically a picking or stocking station where product items are taken out of or placed into the storage container 106. At the picking or stocking station, the storage container 106 is not usually removed from the automated storage and retrieval system 1, but once accessed, it is returned to the grid 104. Ports can also be used to move the storage container in and out of the grid 104, for example, to move the storage container 106 to another storage facility (e.g., to another grid or another automated storage and retrieval system), a transport vehicle (e.g., a train or truck), or a production facility.

[0021] Conveyor systems equipped with conveyors are typically used to transport storage containers between ports 119 and 120 and access stations.

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

[0023] The conveyor system may be configured to transport storage containers 106 between different grids, for example, as described in International Publication No. 2014 / 075937A1, the contents of which are incorporated herein by reference.

[0024] When a storage container 106 stored in grid 104 disclosed in Figure 1 is to be accessed, one of the container handling vehicles 201, 301 is instructed to retrieve the target storage container 106 from its position in grid 104 and transport it to the drop-off port 119. This operation includes moving the container handling vehicle 201, 301 to a grid position above the storage column 105 where the target storage container 106 is located, using a lift device (not shown) on 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 drop-off port 119. If the target storage container 106 is located deep within the stack 107, i.e., if one or more other storage containers 106 are located above the target storage container 106, the operation also includes temporarily moving the storage containers located above before lifting the target storage container 106 from the storage column 105. This step, sometimes referred to as "mining" in the art, may be performed by the same container handling vehicle that will subsequently be used to transport the target storage container to the drop-off port 119, or by one or more other cooperating container handling vehicles. Alternatively, or additionally, the automated storage retrieval system 1 may have a container handling vehicle dedicated to the task of temporarily removing storage containers from the storage column 105. Once the target storage container 106 is removed from the storage column 105, the temporarily removed storage container may be repositioned to its original storage column 105. However, the removed storage container may be repositioned to another storage column instead.

[0025] When a storage container 106 is to be stored in grid 104, one of the container handling vehicles 201, 301 is instructed to pick up the storage container 106 from the pickup port 120 and transport it to a grid position above the storage column 105 where it should be stored. After any storage containers located in or above the target position in the storage column stack 107 have been removed, the container handling vehicles 201, 301 place the storage container 106 in the desired position. The removed storage container may then be returned to the storage column 105 or relocated to another storage column.

[0026] To monitor and control the automated storage and retrieval system 1, for example, to monitor and control the position of each storage container 106 in the grid 104, the contents of each storage container 106, and the movement of the container handling vehicles 201, 301, so that the desired storage containers 106 can be delivered to the desired location at the desired time without the container handling vehicles 201, 301 colliding with each other, the automated storage and retrieval system 1 includes a control system that is typically computerized and typically includes a database for tracking the storage containers 106.

[0027] It is important that the grid on which container handling vehicles operate is level and that the conditions are good for the system to function properly. Therefore, when constructing the grid, it is important that the floor is strong enough to support the weight and that the floor is level in order to ensure that container handling vehicles can travel safely and operate properly on the grid.

[0028] Grid failures can be serious enough to affect the operation of container handling robots. Because failures typically develop slowly over time, the grid condition needs to be monitored regularly. If not checked, such failures can be of a nature that could halt or even damage container handling vehicles, leading to grid closure for repairs.

[0029] Another problem related to grids having defects in the form of height differences between cells of the grid and further between different vertical members of the grid is that it can lead to wear and breakage of different parts of the storage system. The container can be damaged by rubbing against the side of the column, and the column can be damaged by abrasion of the container. Further, the lift platform of the container handling vehicle can be damaged when it hits the vertical member of the column during the raising and lowering of the container to and from the grid. Also, the container handling vehicle can be damaged due to the non-uniform grid. For example, when the wheels are not in contact with the grid during transportation, the wheels and the motor supplying power to the wheels can be damaged.

Prior Art Documents

Patent Documents

[0030]

Patent Document 1

Summary of the Invention

Means for Solving the Problems

[0031] Summary of the Invention The present invention is characterized by what is described in the independent claims, and the dependent claims describe other features of the present invention.

[0032] In one aspect, the present invention is a method for measuring a level deviation in an automated storage and retrieval system, wherein the system A rail system comprising: a first set of parallel rails positioned across the top of a frame structure to guide the movement of a container handling vehicle in a first direction (X); a second set of parallel rails positioned perpendicular to the first set of rails to guide the movement of a container handling vehicle in a second direction (Y) perpendicular to the first direction (X), wherein the first and second sets of parallel rails divide the rail system into a plurality of grid cells; and at least one container handling vehicle configured to operate on the rail system, wherein the at least one container handling vehicle is provided with at least one orientation sensor configured to measure at least one orientation parameter of a sensor in a three-dimensional Cartesian coordinate system; and the container handling vehicle The method comprises a central control unit configured to receive, transmit and process data signals and to receive and process data signals from sensors, and the method includes the steps of: positioning a container handling vehicle at a predetermined location on a grid; transmitting a data signal from the central control unit to the container handling vehicle to instruct the container handling vehicle to move a predetermined distance in one direction (X,Y) along the grid; using an orientation sensor to measure at least one orientation parameter at predetermined intervals to generate orientation measurements indicating the orientation of the container handling vehicle in a three-dimensional Cartesian coordinate reference system; transmitting data relating to the orientation measurements to the central control unit; and using the central control unit to process the orientation measurements to identify portions of the rail system that deviate from predetermined values.

[0033] Further measurements of orientation parameters are performed using orientation sensors in the form of tilt sensors to measure the tilt of the container handling robot relative to Earth's gravity in the X and Y directions, respectively.

[0034] The pitch (φ) and roll (Θ) of the container handling vehicle in each column of the grid are measured.

[0035] An inertial measurement unit (IMU) fixed to the container handling vehicle is used to measure the pitch (φ) and roll (Θ) of the container handling vehicle in each column of the grid.

[0036] This includes the step of calculating the height differences ΔHx and ΔHy between the average heights of each side of individual grid cells.

[0037] formula [ka] The magnitude of skewness in individual grid cells is calculated from the orientation measurements using this method.

[0038] formula [ka] The magnitude of skewness in individual grid cells is calculated from the orientation measurements using this method.

[0039] A map is generated using the magnitude of the skewness of each individual grid cell.

[0040] The level of deviation for each grid cell is plotted on a map, and the map is output.

[0041] Different colors are used to indicate the severity of level deviations in grid cells.

[0042] Container handling vehicles are used to take measurements at predetermined intervals, where each predetermined interval is one grid cell in the rail system.

[0043] Multiple container handling vehicles operating on a rail system, each provided with at least one orientation sensor, and each of the multiple container handling vehicles transmits orientation measurements to a central control unit, enabling simultaneous determination of level deviations of grid cells in different areas of the rail system while the container handling vehicles handle containers in an automated storage and retrieval system.

[0044] A container handling vehicle is used to measure deviations in the rail system while it is operating normally.

[0045] Maintaining a level rail system in an automated storage and recovery system, comprising using a method for measuring a level deviation in an automated storage and recovery system as described in any of the preceding claims, wherein the method of maintenance includes adjusting the upright members of the column using the measured values.

[0046] In a second aspect, the present invention relates to a system for measuring level deviation in an automated storage and retrieval system, the rail system comprising: a first set of parallel rails arranged to guide the movement of a container handling vehicle in a first direction (X) traversing the top of a frame structure; and a second set of parallel rails arranged perpendicular to the first set of rails to guide the movement of a container handling vehicle in a second direction (Y) perpendicular to the first direction (X), wherein the first and second sets of parallel rails divide the rail system into a plurality of grid cells; and at least one container handling vehicle configured to operate on the rail system, wherein the at least one container handling vehicle measures at least one orientation of a sensor in a three-dimensional Cartesian coordinate system. The present invention relates to a system comprising: at least one container handling vehicle provided with at least one orientation sensor configured to measure parameters; and a central control unit configured to receive, transmit and process data signals from the container handling vehicle and to receive and process data signals from the sensor, wherein the container handling vehicle is positioned in a predetermined location on a grid, the central control unit transmits data signals to the container handling vehicle to instruct the container handling vehicle to move along the grid, the orientation sensor measures at least one orientation parameter at predetermined intervals and transmits data regarding the orientation measurement to the central control unit, and the central control unit processes the orientation measurement to identify portions of the rail system that deviate from predetermined values.

[0047] In a third aspect, the present invention relates to a map that displays the deviation level of each grid cell in an automated storage and retrieval system. This specification also provides, for example, the following: (Item 1) A method for measuring level deviations in an automated storage and recovery system, wherein the system is A rail system comprising: a first set of parallel rails positioned across the top of a frame structure to guide the movement of a container handling vehicle in a first direction (X); and a second set of parallel rails positioned perpendicular to the first set of rails to guide the movement of the container handling vehicle in a second direction (Y) perpendicular to the first direction (X), wherein the first and second sets of parallel rails divide the rail system into a plurality of grid cells; At least one container handling vehicle configured to operate on the rail system, wherein the at least one container handling vehicle is provided with at least one orientation sensor configured to measure at least one orientation parameter of a sensor in a three-dimensional Cartesian coordinate reference system, A central control unit configured to receive, transmit and process data signals from the container handling vehicle, and to receive and process data signals from the sensor, Equipped with, The aforementioned method, The steps include: positioning the container handling vehicle at a predetermined location on the grid; The steps include transmitting a data signal from the central control unit to the container handling vehicle to instruct the container handling vehicle to move a predetermined distance in one direction (X,Y) along the grid, The steps include: using the orientation sensor to measure at least one orientation parameter at predetermined intervals and generating orientation measurements that indicate the orientation of the container handling vehicle within a three-dimensional orthogonal coordinate reference system; The steps include transmitting the data relating to the orientation measurement to the central control unit, The steps include: processing the orientation measurement using the central control unit to identify a portion of the rail system that deviates from a predetermined value; Methods that include... (Item 2) The method according to item 1, wherein measuring the orientation parameter is performed using an orientation sensor in the form of a tilt sensor for measuring the tilt of the container handling robot with respect to Earth's gravity in the X direction and the Y direction, respectively. (Item 3) The method according to any of the preceding items, comprising measuring the pitch (φ) and roll (Θ) of the container handling vehicle in each column of the grid. (Item 4) The method according to any of the preceding items, wherein the pitch (φ) and roll (Θ) of the container handling vehicle in each column of the grid are measured using an inertial measurement unit (IMU) fixed to the container handling vehicle. (Item 5) A method according to any of the preceding items, comprising the step of calculating the height difference ΔHx and ΔHy between the average heights of each side of an individual grid cell. (Item 6) The magnitude of the skewness of each grid cell is given by the following formula

number

number

[0048] The following drawings are attached to facilitate understanding of the present invention. The drawings illustrate embodiments of the present invention and are described here only as examples.

[0049] [Figure 1] Figure 1 is a perspective view of the framework structure of a conventional automated storage and retrieval system. [Figure 2] Figure 2 is a perspective view of a conventional container handling vehicle having a centrally located cavity for transporting storage containers inside. [Figure 3] Figure 3 is a perspective view of a conventional container handling vehicle having a cantilever beam for transporting storage containers downwards. [Figure 4] Figure 4 is a plan view in the X and Y directions of the grid cells of a rail system showing a single-track rail system. [Figure 5] Figure 5 is a plan view of a grid cell in a rail system, showing rails with two tracks in the X direction and rails with two tracks in the Y direction. [Figure 6] Figure 6 is a more detailed plan view of the grid cells. [Figure 7] Figure 7 is a schematic diagram of an embodiment of a system for logging orientation measurements. [Figure 8] Figure 8 is a perspective view of orientation measurements representing the tilt of a container handling vehicle positioned on a grid cell, performed by a container handling vehicle without a pendulum. [Figure 9] Figure 9 is a perspective view of orientation measurements representing the tilt of a container handling vehicle positioned on a grid cell, executed by a container handling vehicle with a pendulum. [Figure 10] Figure 10 shows a rail system where level deviations (e.g., skewness) in different grid cells are displayed in the form of a heatmap. [Figure 11] Figure 11 shows a rail system in which the height differences between different grid cells are displayed in the form of a topographic map. [Modes for carrying out the invention]

[0050] Detailed description of the invention Embodiments of the present invention will be described in more detail below with reference to the attached drawings. However, it should be understood that the drawings are not intended to limit the present invention to the subject matter shown in the drawings.

[0051] While this specification describes the use of wheels, it should be understood that other types of drive mechanisms can also be used. Examples include, for instance, endless tracks or any form of continuous track.

[0052] The framework structure 100 of the automatic storage and retrieval system 1 is constructed according to the prior art framework structure 100 described above in relation to Figures 1 to 3, namely several upright members 102 and several horizontal members 103 supported by the upright members 102, and furthermore, the framework structure 100 includes a first upper rail system 108 in the X and Y directions.

[0053] The framework structure 100 further comprises storage compartments in the form of storage columns 105 provided between members 102 and 103, and storage containers 106 are stackable in stacks 107 within the storage columns 105.

[0054] The framework structure 100 can be of any size. In particular, it is understood that the framework structure can be considerably wider and / or longer and / or deeper than disclosed in Figure 1. For example, the framework structure 100 may have a horizontal range exceeding 700 × 700 columns and a storage depth of more than 12 containers.

[0055] One embodiment of a method for measuring level deviation in an automated storage and recovery system according to the present invention will be described in more detail with reference to Figures 7 to 10.

[0056] In the preceding description, various aspects of the container handling vehicle and automated storage and retrieval system according to the present invention have been described with reference to exemplary embodiments. For explanatory purposes, specific numbers, systems, and configurations have been described to provide a complete understanding of the system and its operation. However, this description is not intended to be constrained. Various modifications and variations of the exemplary embodiments, as well as other embodiments of the system that are obvious to those skilled in the art to which the disclosed subject matter relates, are considered to be within the scope of the present invention.

[0057] Figure 7 is a schematic diagram of a system for logging orientation measurements. This diagram shows one or more sensors 701 and the flow of data from the sensors to the logging equipment. The logger 702 reads the data, adds a timestamp, and then records it in the log 703. The logger 702 and log 703 may reside on a remote computer 704.

[0058] The logger 702 operates each time the container handling vehicle makes a stop during the measurement run. In a preferred embodiment of the present invention, the container handling vehicle moves column by column on the grid and performs measurements. For each column, the sensor performs the necessary measurements. The logger can be located on the container handling vehicle, or it can be located on a central computer system.

[0059] Measurements are performed using sensors to measure the inclination of the grid cells against gravity, and therefore the storage columns below. The inclination of the grid cells may be affected by the movement of the upright members that define the position of the grid cell corners. The upright members may shift, may deform due to thermal and load cycles, the ground may shift, or may have stabilization issues. All of these are reasons why the tops of the grid cells in an automated storage and retrieval system may become uneven over time. At least one sensor on a container handling vehicle may be used to measure whether and by how much the rails above the storage columns deviate from the horizontal level. Measurements may be performed by at least one container handling vehicle handling containers that are retrieved and returned for storage in an automated storage and retrieval system while moving along the rails through the grid space from one storage column to the next. Alternatively, measurements may be produced by at least one container handling vehicle performing survey work rather than a normal container handling mission. Measurements can be performed such that the entire grid of the rail system is first scanned cell by cell by one or more container handling vehicles, and then the data is updated as the container handling vehicles repeat the route while performing their normal duties. In this way, it is possible to continuously update information regarding the state of the grid space of the rail system.

[0060] If a problem is identified in a part of the rail system where the inclination of one or more of the grid cells is so severe that there is a risk of container handling vehicles running on that part of the grid and causing accidents such as derailments, or experiencing problems raising and lowering storage containers within the storage columns, the problem can be mitigated by adjusting the height of the upright members of that part of the grid, or by making any other modifications to ensure that the plane created by the rails at the top of the grid is as close to horizontal as possible.

[0061] In a preferred embodiment of the present invention, the sensor 701 may be an inertial measurement unit (hereinafter referred to as IMU). An inertial measurement unit (IMU) is an electronic device that uses a combination of an accelerometer, a gyroscope, and optionally a magnetometer to measure and report specific forces, angular velocities, and optionally body orientation of a body. The advantage of using an IMU is that it is inexpensive, as it allows the IMU unit to be incorporated into all container handling vehicles. This allows the container handling vehicle to continuously monitor the status of grid cells and rail systems.

[0062] In a further embodiment of the present invention, one or more of the sensors may be precision tilt sensors. A precision tilt sensor measures the tilt of each grid cell by measuring the pitch and roll of the container handling vehicle as it passes over or stands within that particular grid cell. Because precision tilt sensors are highly accurate but also expensive, it is unlikely that all container handling vehicles will be equipped with them. Therefore, this sensor may not be practical for continuously measuring the grid condition while the container handling vehicle is performing its routine tasks, but it may be used at periodic intervals.

[0063] Instead of sensors being permanently mounted on one or more container handling vehicles, at least one sensor and communication unit may be located in a box or unit that communicates measurements to a grid survey unit, performs data and calculation logging, and can be handled by the gripper unit of the container handling vehicle.

[0064] Figure 8 is a perspective view of the inclination measurements of a container handling vehicle positioned in grid space, performed by a container handling vehicle without a pendulum.

[0065] A container handling vehicle has two wheels on each of its four sides. Therefore, there are four wheels for transporting the container handling vehicle in the X direction and four wheels for transporting the container handling vehicle in the Y direction.

[0066] In container handling vehicles without a pendulum mechanism, the wheel sets used to transport the container handling vehicle in the X or Y direction are always fixed relative to each other. That is, all wheels in the same direction are either fixed to the body of the container handling vehicle or all move up and down by the same distance.

[0067] This solution does not guarantee that all wheels in one direction are in contact with the rails simultaneously. If the height difference between the upright members within the column is significant, the container handling vehicles moving along the storage system may become unstable, potentially leading to deviations, for example, which could result in a prolonged system shutdown to resolve the issue.

[0068] When calculating the deviation of grid cells, and therefore the deviation of the height of the upright members of the column, the lengths of the rails in both the X and Y directions (length X and length Y in equations III and IV) are considered first, and the length of the rails in each grid cell direction is known to the system in advance. Then, the inclination of the container handling vehicle is measured. From these two sets of parameters, it is possible to calculate the height deviation between different upright members at a specific height of each upright member.

[0069] This method simulates a pendulum-less robot, i.e., a container handling vehicle, and calculates the average angle of the cells. For each cell, the height difference ΔHx and ΔHy between the average heights of each side of the cell are first calculated, as shown in equations I and II. [ka] Next, pitch and roll are calculated using equations III and IV, respectively. [ka]

[0070] An overview of the variables is shown in Figure 8, where pitch and roll are represented as φ and Θ, respectively.

[0071] Figure 9 is a perspective view of the measurement of the inclination of a container handling vehicle positioned on a column, performed by a container handling vehicle with a pendulum.

[0072] A container handling vehicle with a pendulum is a vehicle that has ball bearings between two parallel wheel sections. The pendulum ensures that the container handling vehicle has all wheels in one direction in contact with the track, even if the column tracks do not have the same incline.

[0073] Figure 9 discloses a method for calculating the height difference between each column using a container handling vehicle with a pendulum. The robot with the pendulum calculates the angle directly on the rail. First, the height difference between the upright members in the x and y directions is calculated as shown in equations V and VI. [ka]

[0074] Subsequently, pitch and roll are calculated using equations III and IV.

[0075] An overview of the variables is shown in Figure 9, where pitch and roll are denoted as φ and Θ, respectively.

[0076] For both container handling vehicles without a pendulum (Figure 8) and container handling vehicles with a pendulum (Figure 9), the heatmap (i.e., the skewness map) has only one value per cell, resulting in a total of two angles and two delta heights. Therefore, there needs to be a way to highlight the level of skewness in each grid cell. There are several ways to convert these two values ​​into a single value in the heatmap.

[0077] The absolute value of the height difference within a cell is calculated using equations VII and VIII. [ka]

[0078] In a preferred embodiment of the present invention, the magnitude of the skewness of a single cell is calculated using formula IX. [ka]

[0079] In an alternative embodiment of the present invention, equation X can be used to calculate the magnitude of the skewness of a single grid cell. [ka]

[0080] Figure 10 is a diagram of a grid-based rail system showing the height differences of different columns. Here, you can see that the height differences of the columns are displayed in a heatmap. The heatmap provides an indication of where anomalies are located in the rail system detected by container handling vehicles and how serious the anomalies are. The severity of the anomaly is indicated by color. Alternatively, it can be represented by shades of gray or line intensity. The color, shade of gray, or line intensity (or other form of graphical representation) shown in the grid cells can indicate whether action is required to correct the anomaly. It can also indicate whether immediate action is required or whether the grid operation can be maintained, for example, by slowing down.

[0081] Figure 11 is a diagram of a rail system in which the height differences between different grid cells are displayed in the form of a topographic map. The topographic map is a 3D display of the height differences of the grid. The map can display the height difference of each vertical member of the grid, and the height difference is relative to a theoretical flat grid.

[0082] This solution also allows for tracking the occurrence of anomalies over time. If an anomaly occurs where the area of ​​the grid increases over time, it can be an indicator of settlement damage. If there is a sudden appearance of an anomaly, it may indicate a problem with one or more of the upright members in the column. This could indicate impact damage that bent one or more of the upright members, or it could be an indicator of damage due to fatigue or motion due to heat or load cycling, for example. By studying the map and measurement history, it is possible to indicate the type of damage, what kind of treatment is needed, and how quickly it should be carried out.

[0083] Measurements can be performed periodically by one or more container handling vehicles equipped with sensors that take measurements periodically while the grid is not in operation. Alternatively, sensors can be attached to one or more container handling vehicles that are operating normally on the grid, allowing measurements to be taken while they perform their normal tasks on the grid-based rail system.

[0084] The collected data can be used internally by the owner of the automated storage and retrieval system, or it can be shared in a global database. The collected data can be used to indicate the types of problems that may occur and the best way to repair them. If there is a settling problem in the rail system, knowledge can be gained about how to avoid this type of damage in the future, and information on how to solve the problem can be stored in the database. If there is a fatigue damage or failure problem in the equipment, it is useful information to collect to indicate who is best suited to solve the problem, whether it be the equipment manufacturer or if there is a problem with the design of a different part of the storage grid.

[0085] Another method for measuring the angle of cells within a storage system is to use a container handling vehicle with a suspension system on the wheels, such as a pendulum-type solution. This solution can measure the height difference between the wheels and calculate the angle that the difference makes with respect to the horizontal.

[0086] The pendulum-type solution mentioned for container handling vehicles can be replaced with a suspension system. Any type of suspension system can be used.

[0087] If an area of ​​the grid exhibiting anomalies is detected, this area can be compared to the weight of containers within that area with the weight of container handling vehicles on the grid within that area. If the weights of containers and container handling vehicles within that area match the uneven weight distribution of the grid, that portion of the grid can be set up under limited use, for example, by instructing container handling vehicles to obtain a similar weight from containers stored in another portion of the grid as that stored in the containers within the affected area. It is further possible to limit the number of container handling vehicles operating in the affected portion of the grid. It is also possible to restrict the movement of container handling vehicles within that area. Container handling vehicles can be instructed not to change direction within the affected area, for example, by slowing down and operating with slower acceleration and deceleration. (List of reference numbers)

[0088] [Table 1-1] [Table 1-2]

Claims

1. A method for measuring level deviations in an automated storage and recovery system, wherein the system is A rail system comprising: a first set of parallel rails positioned across the top of a frame structure to guide the movement of a container handling vehicle in a first direction (X); and a second set of parallel rails positioned perpendicular to the first set of rails to guide the movement of the container handling vehicle in a second direction (Y) perpendicular to the first direction (X), wherein the first and second sets of parallel rails divide the rail system into a plurality of grid cells; At least one container handling vehicle configured to operate on the rail system, wherein the at least one container handling vehicle is provided with at least one orientation sensor configured to measure at least one orientation parameter of a sensor in a three-dimensional Cartesian coordinate system, A central control unit configured to receive, transmit and process data signals from the container handling vehicle, and to receive and process data signals from the sensor, Equipped with, The aforementioned method, The steps include: positioning the container handling vehicle at a predetermined location on the grid; The steps include transmitting a data signal from the central control unit to the container handling vehicle to instruct the container handling vehicle to move a predetermined distance in one direction (X, Y) along the grid, The steps include: using the orientation sensor to measure at least one orientation parameter at predetermined intervals and generating orientation measurements that indicate the orientation of the container handling vehicle within the three-dimensional orthogonal coordinate reference system; The steps include transmitting the data relating to the orientation measurement to the central control unit, The steps include: processing the orientation measurement using the central control unit to identify a portion of the rail system that deviates from a predetermined value; Methods that include...

2. The method according to claim 1, wherein measuring the orientation parameter is performed using an orientation sensor in the form of a tilt sensor for measuring the tilt of a container handling robot with respect to Earth's gravity in the X direction and the Y direction, respectively.

3. The method according to any one of claims 1 to 2, comprising measuring the pitch (φ) and roll (Θ) of the container handling vehicle in each column of the grid.

4. The method according to claim 3, wherein measuring the pitch (φ) and roll (Θ) of the container handling vehicle in each column of the grid is performed using an inertial measurement unit (IMU) fixed to the container handling vehicle.

5. The method according to any one of claims 1 to 4, comprising the step of calculating the height differences ΔHx and ΔHy between the average heights of each side of an individual grid cell.

6. The magnitude of the skewness of each grid cell is given by the following formula [Math 1] The method according to claim 5, calculated from the orientation measurement using

7. The magnitude of the skewness of each grid cell is given by the following formula [Math 2] The method according to claim 5, calculated from the orientation measurement using

8. The method according to claim 6 or 7, comprising generating a map using the magnitude of the skewness of individual grid cells.

9. The method according to claim 8, comprising plotting the deviation level of each grid cell in the map and outputting the map.

10. The method according to claim 9, comprising using different colors to indicate the severity of level deviations in grid cells.

11. The method according to any one of claims 1 to 10, comprising measuring at predetermined intervals using a container handling vehicle, wherein the predetermined interval is each individual grid cell of the rail system.

12. The method according to claim 11, wherein there are a plurality of container handling vehicles operating on the rail system, each of the plurality of container handling vehicles is provided with the at least one orientation sensor, and each of the plurality of container handling vehicles transmits orientation measurements to the central control unit, thereby enabling the level deviation of grid cells in different areas of the rail system to be determined simultaneously while the container handling vehicles are handling containers of the automated storage and retrieval system.

13. The method according to any one of claims 1 to 12, comprising using a container handling vehicle to measure the deviation of the rail system while it is performing normal operations.

14. A method for maintaining a level rail system in an automated storage and retrieval system, the method comprising using a method for measuring a level deviation in an automated storage and retrieval system according to any one of claims 1 to 13, the maintenance method comprising adjusting the upright members of a column using the measured value.

15. A system for measuring level deviation in an automated storage and retrieval system, the system comprising a rail system comprising: a first set of parallel rails arranged to guide the movement of a container handling vehicle in a first direction (X) traversing the top of a frame structure; and a second set of parallel rails arranged perpendicular to the first set of rails to guide the movement of the container handling vehicle in a second direction (Y) perpendicular to the first direction (X), wherein the first and second sets of parallel rails divide the rail system into a plurality of grid cells; and at least one container handling vehicle configured to operate on the rail system, wherein the at least one container handling vehicle measures at least one orientation parameter of a sensor in a three-dimensional Cartesian coordinate system. A system comprising at least one container handling vehicle provided with at least one orientation sensor configured to receive, transmit and process data signals from the container handling vehicle and a central control unit configured to receive and process data signals from the sensor, wherein the container handling vehicle is positioned at a predetermined location on the grid, the central control unit transmits data signals to the container handling vehicle to instruct the container handling vehicle to move along the grid, the orientation sensor measures at least one orientation parameter at predetermined intervals, transmits data relating to the orientation measurement to the central control unit, and processes the orientation measurement using the central control unit to identify portions of the rail system that deviate from predetermined values.

16. A map displaying the deviation level of each grid cell in an automated storage and recovery system generated by the method according to claims 1 to 14 and the system according to claim 15.

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