A device for retrieving units from a storage system.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- OCADO INNOVATION LTD
- Filing Date
- 2025-06-05
- Publication Date
- 2026-08-03
Smart Images
Figure 0007899405000001 
Figure 0007899405000002 
Figure 0007899405000003
Abstract
Description
Technical Field
[0001] The present invention relates to an apparatus for retrieving units from a storage system. Specifically, but not exclusively, the present invention relates to a robotic device for handling storage containers or storage boxes in a storage vault comprising a grid of stacked units.
Background Art
[0002] Some commercial and industrial activities require systems that enable the storage and retrieval of a number of different products. One known system for the storage and retrieval of items in multiple product lines involves placing storage boxes or storage containers in rows of shelves arranged in aisles. Each box or container holds multiple products of one product type. The aisles provide access between the rows of shelves so that the required products can be retrieved by a worker or robot traversing the aisles. However, it will be understood that the need to provide aisle space to access the products means that the storage density of such systems is relatively low. Put another way, the size of the space actually used for storing products is relatively small compared to the size of the space required for the overall storage system.
[0003] Another approach that provides a significant improvement in storage density is where containers are stacked on top of each other and the stacks are arranged in rows. The containers are accessed from above, eliminating the need for aisles between the rows and allowing more containers to be stored in a given space.
[0004] Methods for handling stacked containers have been well-known for decades. In some such systems, such as those described in U.S. Patent No. 2,701,065, unsupported stacks of containers are arranged in rows to reduce the storage volume associated with storing such containers while providing access to specific containers when needed. Access to a given container is made possible by providing a relatively complex lifting mechanism that can be used to stack the containers and to remove a given container from the stack. However, the cost of such systems is impractical in many situations and they are primarily commercialized for the storage and handling of large shipping containers.
[0005] The concept of using unsupported stacks of containers and providing a mechanism for retrieving and storing specific containers has been further developed, as described, for example, in EP0767113B (Cimcorp). Cimcorp discloses a mechanism for retrieving multiple stacked containers using a robotic loader, in the form of a rectangular tube configured to be lowered in height around the stack and to grip containers at any height in the stack. In this method, several containers may be lifted from the stack in a single step. The movable tube may be used to move several containers from the top of one stack to the top of another stack, or to move containers from a stack to an external location, or from an external location to a stack. Such a system may be particularly useful when all containers in a single stack contain the same product (understood as a single-product stack). The loader may be used to move containers between single-product stacks, for example, to add multiple containers containing a single type of product to a storage facility, and to retrieve one or more containers from two or more single-product stacks to create a multi-product shipping stack. This example involves obtaining wooden crates of vegetables from a central warehouse in order to create an order for multiple products to be delivered to a retail store.
[0006] In the system described by Cimcorp, the height of the tubing must be at least the same as the height of the highest stack of containers so that the tallest stack of containers can be extracted in a single run. Therefore, when used in enclosed spaces such as warehouses, the maximum stack height is limited by the need to accommodate the tubing of the loading machine. Furthermore, the system is not well-suited for selecting a single container from a stack of multiple products.
[0007] Online retail businesses that sell multiple product categories, such as online grocery stores and supermarkets, require systems capable of storing tens or even hundreds of thousands of different product categories. In such cases, using single-product stacking is impractical because it would require a very large amount of floor space to accommodate all the necessary stacks. Furthermore, some items, such as perishable goods or items ordered infrequently, may only need to be stored in small quantities, making single-product stacking an inefficient solution.
[0008] Therefore, for certain applications, the use of multi-product stacks, where each stack can hold different products, is preferred to maximize the storage density of the system. The stored items must remain reasonably quick and easy to access so that multiple different items required to fulfill a customer order can be retrieved from the storage system in an efficient manner, even if some of the required items are stored in lower heights of the stack beneath other containers.
[0009] International patent application WO98 / 049075A (Autostore), the contents of which are incorporated herein by reference, describes a system in which the stacking of multiple products in containers is arranged inside a frame structure. This type of system is schematically shown in Figures 1 to 4 of the attached drawings.
[0010] As shown in Figures 1 and 2, stackable containers, understood as boxes 10, are stacked on top of each other to form a stack 12. The stack 12 is located in a grid frame structure 14 in a warehouse or manufacturing environment. Figure 1 is a schematic perspective view of the frame structure 14, and Figure 2 is a top-down view of the stack 12 of boxes 10 located within the frame structure 14. Each box 10 typically holds multiple product items (not shown), and the product items in the boxes 10 may be identical or of different product types depending on the application.
[0011] The frame structure 14 comprises a plurality of upright members 16 that support horizontal members 18, 20. A first set of parallel horizontal members 18 are positioned perpendicular to a second set of parallel horizontal members 20 to form a plurality of horizontal lattice structures supported by the upright members 16. The members 16, 18, 20 are typically made of metal. The boxes 10 are stacked between the members 16, 18, 20 of the frame structure 14 so that the frame structure 14 protects the stack 12 of boxes 10 from horizontal movement and guides the vertical movement of the boxes 10.
[0012] The top height of the frame structure 14 is provided with rails 22 arranged in a grid pattern across the top of the stack 12. Referring further to Figures 3 and 4, the rails 22 support multiple robotic load handling devices 30. A first set 22a of parallel rails 22 guides the movement of the load handling devices 30 in a first direction (X) across the top of the frame structure 14, and a second set 22b of parallel rails 22, positioned perpendicular to the first set 22a, guides the movement of the load handling devices 30 in a second direction (Y) perpendicular to the first direction. In this manner, the rails 22 allow the movement of the load handling devices 30 in two dimensions laterally in the horizontal XY plane, so that the load handling devices 30 can be moved to any position above the stack 12.
[0013] The cargo handling device 30 is further described in Norwegian Patent No. 317366, the details of which are incorporated herein by reference. Figures 3(a) and 3(b) are schematic perspective views of the cargo handling device 30 from the rear and front, respectively, and Figure 3(c) is a schematic front perspective view of the cargo handling device 30 lifting the box 10.
[0014] Each load handling device 30 comprises a vehicle 32 positioned above the stack 12, moving in the X and Y directions on rails 22 of the frame structure 14. The first set of wheels 34 consists of a pair of wheels 34 on the front side of the vehicle 32 and a pair of wheels 34 on the rear side of the vehicle 32, and is positioned to engage with two adjacent rails of the first set 22a of rails 22. Similarly, the second set of wheels 36 consists of a pair of wheels 36 on each side of the vehicle 32, and is positioned to engage with two adjacent rails of the second set 22b of rails 22. Each set of wheels 34, 36 can be raised and lowered so that either the first set of wheels 34 or the second set of wheels 36 engages with the respective set of rails 22a, 22b at any given time.
[0015] When the first set of wheels 34 engages with the first set 22a of rails and the second set of wheels 36 is lifted away from rails 22, the wheels 34 may be driven using a drive mechanism (not shown) housed in the vehicle 32 to move the load handling device 30 in the X direction. To move the load handling device 30 in the Y direction, the first set of wheels 34 is lifted away from rails 22 and the second set of wheels 36 is lowered to engage with the second set 22b of rails. The drive mechanism may then be used to drive the second set of wheels 36 to achieve movement in the Y direction.
[0016] The cargo handling device 30 is equipped with a crane device 40. The crane device 40 has a cantilever arm 42 that extends laterally from the top of the vehicle 32. A gripping plate 44 is suspended from the cantilever arm 42 by four cables 46. The cables 46 are connected to a winding mechanism (not shown) housed inside the vehicle 32. The cables 46 may be wound in or unwound from the cantilever arm 42 so that the position of the gripping plate 44 relative to the vehicle 32 can be adjusted in the Z direction.
[0017] The gripping plate 44 is fitted to engage with the top of the box 10. For example, the gripping plate 44 may include a pin (not shown) that engages with a corresponding hole (not shown) in the edge forming the top surface of the box 10, and a sliding clip (not shown) that can engage with the edge to grip the box 10. The clip is driven to engage with the box 10 by a suitable drive mechanism housed within the gripping plate 44, which is powered and controlled by signals transmitted through the cable 46 itself or through a separate control cable (not shown).
[0018] To retrieve box 10 from the top of the stack 12, the cargo handling device 30 is moved as necessary in the X and Y directions so that the gripping plate 44 is positioned above the stack 12. The gripping plate 44 is then lowered vertically in the Z direction to engage with box 10 at the top of the stack 12, as shown in Figure 3(c). The gripping plate 44 grips box 10 and is then pulled upward by the cable 46 with box 10 attached. At the top of its vertical movement, box 10 is tucked under the cantilever arm 42 and held above the height of the rail 22. In this manner, the cargo handling device 30 can be moved to different positions in the XY plane and box 10 can be carried together with the cargo handling device 30 to transport box 10 to another location. The cable 46 is long enough to allow the cargo handling device 30 to retrieve and place boxes from any height of the stack 12, including floor height. Vehicle 32 is heavy enough to balance the weight of box 10 and to remain stable during the lifting process. The weight of vehicle 32 may consist in part of the batteries used to power the drive mechanisms for wheels 34, 36.
[0019] As shown in Figure 4, multiple identical loading / unloading devices 30 are provided so that each loading / unloading device 30 can operate simultaneously to increase the system's processing capacity. The system shown in Figure 4 includes two specific locations, understood as ports 24, to which boxes 10 can be transported in and out of the system. An additional conveyor system (not shown) is associated with each port 24 so that boxes 10 transported to a port 24 by a loading / unloading device 30 can be transported by the conveyor system to another location, such as a collection station (not shown). Similarly, boxes 10 may be transported by the conveyor system from an external location, such as a box filling station (not shown), to a port 24 to replenish inventory in the system, and then transported by the loading / unloading device 30 to a stack 12.
[0020] Each cargo handling device 30 can lift and move one box 10 at a time. If it is necessary to retrieve a box 10 that is not located on top of the stack 12 ("target box"), the boxes 10 on top of it ("non-target boxes") must be moved first to allow access to the target box 10.
[0021] Each of the cargo handling devices 30 is under the control of a central computer. Each individual box 10 in the system is tracked so that the appropriate box 10 can be retrieved, transported, and replaced as needed.
[0022] The system described with reference to Figures 1-4 has many advantages and is suitable for a wide range of storage and retrieval operations. Specifically, this system enables very dense storage of products and provides a very economical way to store a very wide range of different items in box 10, while also allowing reasonably economical access to all box 10 when retrieval is required.
[0023] For high-capacity systems where operational speed is critical, it is essential to maximize the performance of each load handling device in terms of operating speed, battery life, reliability, lifting capacity, and stability. Therefore, it is desirable to provide load handling devices that offer improved performance in one or more of these areas.
[0024] Also, in order to enable an increase in the rate at which items can be retrieved from the storage system, it may be desirable to increase the number of handling devices used at any time. For example, the applicant's co-pending international patent application PCT / GB2013 / 051215, the contents of which are incorporated herein by reference, describes a storage system in which a plurality of each of two different types of handling devices are provided. One type of handling device is adapted such that, in one operation, it can lift a plurality of boxes from a stack and make the target box in the stack accessible by a second type of single-box handling device. In such a case, it may be desirable to reduce the size of the handling devices in order to minimize the case where the optimal movement path for one device is obstructed by the presence of the other device.
[0025] The present invention has been devised against this background.
Prior Art Documents
Patent Documents
[0026]
Patent Document 1
Patent Document 2
Patent Document 3
Patent Document 4
Patent Document 5
Summary of the Invention
[0027] In one aspect, the present invention relates to a loading handling device for use in a storage system comprising a grid frame that accommodates multiple stacks of containers. The loading handling device is positioned above the stack of containers and can lift the containers from the stack and move them laterally to another location. Advantageously, each loading handling device occupies substantially only a single grid space in the storage system.
[0028] Accordingly, the present invention provides a cargo handling device for lifting and moving stacked containers in a storage system comprising a plurality of rails or tracks arranged in a grid pattern above a stack of containers, wherein the grid pattern comprises a plurality of grid spaces, each stack is located within a footprint of substantially only a single grid space, the cargo handling device is configured to move laterally on rails or tracks above the stack, and the cargo handling device comprises a container receiving space located above the rails or tracks during use, and a lifting device positioned to lift containers from the stack into the container receiving space, wherein the cargo handling device has a footprint that substantially occupies only a single grid space in the storage system during use.
[0029] A cargo handling device according to an embodiment of the present invention includes a container receiving space from which a container can be lifted. The container receiving space is located beneath a vehicle module that houses components such as power components, control components, drive components, and lifting components.
[0030] In a preferred embodiment of the present invention, the cargo handling device has an external housing that substantially encloses the container receiving space. The external housing is preferably cubic in shape.
[0031] By positioning the bulky components of the cargo handling device above the container receiving space, the footprint of the cargo handling device is reduced compared to the cantilever design shown in Figures 3(a) to 3(c) described in Norwegian Patent No. 317366, in which the bulky components are housed in a vehicle module located on one side of the container receiving space. Advantageously, the cargo handling device of the present invention occupies the space above only one stack of containers in the frame, in contrast to the cantilever design shown in Figures 3(a) to 3(c) which occupies the space above two stacks. This means that, thanks to the present invention, the reduced footprint can accommodate more cargo handling devices, and the efficiency of the storage system operation can be improved because one cargo handling device is less likely to obstruct the optimal path of another.
[0032] The cargo handling device preferably includes a set of wheels for supporting the cargo handling device above a stack. For example, the lateral movement of the cargo handling device may be guided by rails arranged above a frame. The rails are arranged in a grid pattern to allow two-dimensional movement of the cargo handling device in a horizontal plane. The wheels can engage with the rails. There may be two sets of wheels, one set of which is arranged to engage with a first set of rails to guide the movement of the cargo handling device in a first direction, and the other set of which is arranged to engage with a second set of rails to guide the movement of the cargo handling device in a second direction.
[0033] In embodiments of the present invention, the wheels are arranged around the container receiving space. The wheels may be driven by one or more motors housed in a vehicle module. The drive may be transmitted from the motors in the vehicle module to the wheels by drive transmission means arranged around the container receiving space. For example, the drive transmission means may comprise a suitable configuration of pulleys and a drive belt.
[0034] Alternatively, the wheels may be equipped with an integrated motor, such as a motor built into the wheel hub. In this method, each wheel is a self-contained drive unit, and a drive belt is not required. This configuration is advantageous for reducing the size of the cargo handling device and facilitating after-sales service.
[0035] The wheels of one or both sets may be configured to be raised and lowered relative to the wheels of the other set. One or more wheel-lifting motors or other wheel-lifting devices may be housed in the vehicle module for this purpose.
[0036] The vehicle module can house a hoisting machine or crane device for lifting containers into the container receiving space. The crane device may have one or more motors for lifting containers, and the motors of the crane device or each of the motors may be housed in the vehicle module.
[0037] The crane device may include a gripping device configured to grip a container from above. The gripping device may be suspended from a cable that can extend from and retract from a vehicle to move the gripping device vertically.
[0038] In another embodiment, the cargo handling device is equipped with a lifting device positioned to lift a single container from a stack into a container receiving space. The lifting device may comprise a pair of lifting arms positioned on either side of the container receiving space, in which case the lifting device may also comprise a gripping device mounted between the ends of the arms and positioned to grip the container from above.
[0039] The cargo handling device preferably has a center of mass that is positioned substantially directly above the gripping device when the gripping device is lowered into the container receiving space.
[0040] In another embodiment, the lifting device comprises a rod or cable positioned to engage with a vertical path formed in the side wall of the container. The path may be accessed through an opening on the top surface of each container. In such a configuration, vertically extending space is not required in the storage system.
[0041] The rod or cable may carry a fastening mechanism that is arranged to releasably engage with the container. For example, the fastening mechanism may include one or more arms that are laterally extendable for engaging with the surface of the container. The fastening mechanism may be operated remotely, for example, by a wire extending through a tubular hole in the rod or cable.
[0042] A cargo handling device according to another embodiment of the present invention comprises an upper section, a lower section including a container receiving space, and a hoisting means for lifting a container into the container receiving space. The hoisting means preferably comprises a hoisting motor housed in the upper section above the container receiving space. The lower section preferably comprises a wheel assembly to facilitate lateral movement of the cargo handling device relative to a frame, and the upper section also comprises at least one motor for driving one or more wheels of the wheel assembly.
[0043] The lower section may include a frame structure for supporting the wheels of the wheel assembly. The frame structure may be arranged around a container receiving space. For example, the container receiving space may be bounded on four sides by the frame structure. One or more elements of the frame structure may be movable to raise and lower the first set of wheels relative to a second set of wheels, thereby facilitating the engagement of either the first set of wheels or the second set of wheels with the first or second set of rails or tracks. The movable elements of the frame structure may be driven by motors housed in the upper part of the load handling device.
[0044] The cargo handling device of the present invention is preferably a self-propelled robotic vehicle.
[0045] In another aspect, the present invention exists in a storage system comprising a frame for accommodating multiple stacks of containers and one or more of the aforementioned loading handling devices. Each loading handling device substantially occupies a single grid space corresponding to the area occupied by a single stack of containers.
[0046] Accordingly, the present invention provides a storage system comprising: a first set of parallel rails or tracks; a second set of parallel rails or tracks extending across the first set in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces; a plurality of stacks of containers positioned below the rails, each arranged such that it occupies substantially the footprint of a single grid space; a load handling device as described above, positioned to move laterally above the stacks on the rails; and a lifting device positioned to lift a single container from the stack into the container receiving space, wherein the load handling device has a footprint that substantially occupies only a single grid space in the storage system.
[0047] In another embodiment, the present invention provides a storage system comprising a frame for accommodating multiple stacks of multiple containers, a first handling device capable of lifting multiple containers from a stack in a single operation, and a second handling device capable of lifting a single container and moving it laterally. The first and second handling devices are positioned above the frame and are independently movable to access different stacks. The second handling device is of the aforementioned type and occupies space substantially corresponding to only one stack of multiple containers.
[0048] In this embodiment, providing a first handling device capable of lifting multiple containers from a stack in a single operation, along with a second handling device capable of lifting a single container and moving the container laterally, provides an optimal solution when attempting to retrieve a container located in the middle or at the bottom of a stack. In such cases, only two lifting operations are required to retrieve the target container, which greatly improves the speed and efficiency of the retrieval process compared to prior art configurations in which only one container can be lifted at a time.
[0049] The storage system may further include one or more port locations from which containers can be removed from and / or added to the storage system. The cargo handling device of the present invention may be capable of transporting target containers from a stack to a port location. The containers may consist of boxes without tops. When the containers are formed in a stack, they may be arranged to connect or engage with each other in the vertical direction.
[0050] In typical applications, multiple handling devices may be used so that multiple containers can be lifted and moved simultaneously. The handling devices may be of different types and may be selected to balance the system's cost and energy consumption with the speed and flexibility of operation. One benefit of the present invention is that, because the handling device occupies the space above only one stack, the efficiency of a multi-device system can be improved compared to prior art handling device designs that occupy two or more stack spaces. The efficiency gain may result from optimizing the routing of the devices using the space gained by the reduced device footprint, or from a combination of these factors, since more handling devices can be accommodated in a given system.
[0051] Preferred and / or optional features of each aspect of the present invention may be used individually or in appropriate combinations of other aspects of the present invention.
[0052] Herein, embodiments of the present invention will be described by example only, with reference to the remaining appended drawings in which similar reference numerals are used for similar features. [Brief explanation of the drawing]
[0053] [Figure 1] Figure 1 is a schematic perspective view of a frame structure for accommodating multiple stacks of boxes in a known storage system. [Figure 2] Figure 2 is a schematic plan view of a portion of the frame structure shown in Figure 1. [Figure 3] Figure 3(a) is a schematic rear perspective view of a known cargo handling device for use with the frame structure of Figures 1 and 2. Figure 3(b) is a schematic front perspective view of a known cargo handling device for use with the frame structure of Figures 1 and 2. Figure 3(c) is a schematic perspective view of a known cargo handling device in use, lifting a box. [Figure 4] Figure 4 is a schematic perspective view of a known storage system comprising multiple cargo handling devices of the types shown in Figures 3(a), 3(b), and 3(c), which are installed on the frame structures of Figures 1 and 2. [Figure 5] Figure 5 is a schematic perspective view of a cargo handling device according to an embodiment of the present invention. [Figure 6] Figure 6(a) is a schematic perspective view of the cargo handling device from Figure 5, with a portion of the cargo handling device cut away to show the interior of the device. Figure 6(b) is a schematic perspective view of the cargo handling device from Figure 5, with a portion of the cargo handling device cut away to show the interior of the device. Figure 6(c) is a diagram of one possible system structure of the device. [Figure 7] Figure 7 is a schematic perspective view of a storage system comprising a plurality of known cargo handling devices of the type shown in Figures 3(a), 3(b), and 3(c), and a plurality of cargo handling devices of the type shown in Figure 5, installed on the frame structure of Figures 1 and 2. [Figure 8] Figure 8 is a schematic side view of a cargo handling device according to another embodiment of the present invention, with the outer casing omitted. [Figure 9] Figure 9 is a schematic perspective view of a cargo handling device according to another embodiment of the present invention, with the outer casing omitted. [Figure 10] Figure 10 is a schematic top view of a cargo handling device according to another embodiment of the present invention, with the outer casing omitted. [Figure 11] Figure 11 is a schematic perspective view of the cargo handling device shown in Figures 8 to 10, with the outer casing omitted. [Figure 12] Figure 12 is a side view of the cargo handling device shown in Figures 8 to 11. [Figure 13] Figure 13 is a schematic perspective view of a wheel suitable for use with the cargo handling devices shown in Figures 8 to 12. [Figure 14] Figure 14 is a schematic perspective view of a portion of a cargo handling device according to another embodiment of the present invention. [Figure 15] Figure 15 is a schematic perspective view of the internal components of the cargo handling device shown in Figure 14. [Figure 16] Figure 16 is a schematic side view of the internal components of the cargo handling device shown in Figure 14. [Figure 17] Figure 17 is a perspective view of a cargo handling device according to a further embodiment of the present invention. [Modes for carrying out the invention]
[0054] Figure 5 shows a cargo handling device 100 according to an embodiment of the present invention. The cargo handling device 100 comprises a vehicle 102 equipped with a hoisting machine or crane mechanism 104 for lifting storage containers or boxes 106, also known as returnable containers, from above. The crane mechanism 104 comprises a hoisting cable 108 and a gripping plate 110. The gripping plate 110 is configured to grip the top surface of a container 106 in order to lift the container 106 from a stack of containers 106 in the type of storage system shown in Figures 1 and 2.
[0055] Referring also to Figures 6(a) and 6(b), the vehicle 102 comprises an upper section 112 and a lower section 114.
[0056] The lower section 114 is fitted with two sets of wheels 116, 118 that run on rails provided at the top of the storage system frame. At least one wheel from each set 116, 118 is driven to allow the vehicle 102 to move along the rails in the X and Y directions, respectively. As will be described later, one or both sets of wheels 116, 118 can be moved vertically to lift the wheels of each set away from their respective rails, thereby allowing the vehicle 102 to move in the desired direction.
[0057] Wheels 116 and 118 are positioned in the lower section 114 around a cavity or recess 120 known as a container receiving recess. The recess 120 is sized to accommodate the box 106 when it is lifted by the crane mechanism 104, as shown in Figure 6(a). When in the recess 120, the box 106 is lifted away from the rails below so that the vehicle 102 can move laterally to a different location. When it reaches a target location, for example, another stack, an access point in a storage system, or a conveyor belt, the box 106 can be lowered from the recess 120 (as shown in Figure 6(b)) and released from the gripping plate 110.
[0058] The upper section 112 of the vehicle 102, as shown in Figure 6(c), houses all of the significant bulky components of the cargo handling device. The upper section 112 houses the battery and associated electronics, the control and communication devices, the motors for driving the wheels 116 and 118, the motor for driving the crane mechanism 104, and other sensors and systems.
[0059] In this method, the footprint of the vehicle 102 is larger than the dimensions of the box 106, just enough to accommodate the wheels 116, 118 on either side of the recess 120. In other words, the vehicle 102 occupies a single grid space in the storage system. Thus, in this method, the vehicle 102 occupies the smallest possible space in the XY plane and has a footprint approximately half that of the prior art cantilever design shown in Figure 3. For comparison, Figure 7 shows the load handling device 100 according to the present invention in use in the type of storage system shown in Figures 1 and 2, along with the prior art cantilever load handling device 30 of the type shown in Figure 3. It can be seen that the prior art device 30 is shorter in height but occupies twice the stacking space compared to the device 100 of the present invention, which is taller but has a smaller footprint.
[0060] In this invention, since the container load is suspended between pairs of wheels on each side of the vehicle, the load handling device 100 of this invention can also provide improved stability, improved load handling capacity, and reduced weight compared to the cantilevered prior art load handling device 30. In contrast, the prior art device 30 must have a relatively heavy vehicle module in order to balance the load in a cantilevered configuration.
[0061] Figures 8 to 12 show one embodiment of the present invention. The upper section 112 of the vehicle 102 houses three main motors: a Z-axis drive motor 150 used to raise and lower a hoisting cable 108 wound around a spool 109 mounted on a drive shaft installed on the opposite side of the vehicle 102; an X-axis drive motor 152 for driving a first set of wheels 116; and a Y-axis drive motor 154 for driving a second set of wheels 118. The upper section 112 of the vehicle also houses a battery 156 for supplying power to the motors, a control device, sensors, and other components, as previously described with reference to Figure 6(c).
[0062] The drive is transmitted from the X-axis drive motor 152 and the Y-axis drive motor 154 to the wheels 116 and 118 of the respective sets using a belt drive mechanism. The X-axis drive motor 152 drives a pulley 160 connected to a short drive shaft 162 that extends across the vehicle body. The drive is transmitted by the X-axis drive belt 164 from the short drive shaft 162 to each wheel of the first set of wheels 116. The Y-axis drive motor 154 drives a pulley 170 connected to a long drive shaft 172 that extends across the vehicle body perpendicular to the short drive shaft 162. The drive is transmitted by the Y-axis drive belt 174 from the long drive shaft 172 to each wheel of the second set of wheels 118.
[0063] The belt-driven wheels 116 and 118 are mounted on the bottom of the lower part 114 of the vehicle 102. By using drive belts 164 and 174 to transmit power from the motor to the wheels, the motors 152 and 154 can be mounted on the upper part 112 of the vehicle.
[0064] In this embodiment, the first set of wheels 116 can be raised away from or lowered onto the rails using a wheel positioning mechanism, as most clearly shown in Figures 9, 11, and 12. Each wheel 116 is mounted on an arm 180 which is pivotally mounted at its outer end. The inner end of each arm 180 is connected to the lower end of a respective link mechanism 182. The upper ends of both link mechanisms 182 are connected to the lower end of a common link mechanism 184. Furthermore, the upper end of the common link mechanism 184 is connected to a lever arm 186 which is driven by a motor 188. By driving the motor 188 to pull the common link mechanism 184 upward, the first set of wheels 116 can be raised so that only the second set of wheels 118 engages with the rails, enabling movement of the vehicle 102 in the Y direction. By operating the motor 188 to push the common link mechanism 184 downward, the first set of wheels 116 moves downward to engage with the rail and lift the vehicle, so that the second set of wheels 118 are lifted away from the rail, as shown in Figures 9, 11, and 12. Thus, the vehicle 102 can move in the X direction.
[0065] The second set of wheels 118 are mounted on fixed T-shaped pieces 190 located at both ends of the lower section 114 of the vehicle 102.
[0066] Figures 8, 9, and 12 show the cargo handling device 100 with the box 106 lifted into the recess 120. Figure 11 shows the cargo handling device 100 with the box 106 below the device 100 and the gripping plate 110 about to engage with the box 106. The wheels 116, 118 and associated support pieces, along with the linkage mechanism and drive belts 164, 174, are positioned around the edge of the recess 120 so that the upper part 112 of the vehicle 102 is firmly supported.
[0067] Figure 13 shows a wheel 200 suitable for use as one of the wheels 116, 118 of the load handling device 100. The wheel 200 has a toothed central path 202 that forms a pulley for cooperating with drive belts 164, 174. The path 202 is bordered by two rubber tires 204 that press against rails during use. The wheel 200 may be mounted on the arm 180 using an axle (not shown) extending through the axle hole 206 of the wheel 200. This wheel design is compact and balanced to minimize wear, and the tires 204 keep the drive belts 164, 174 in a straight line during use.
[0068] Figure 14 shows two wheels 200 mounted on a frame structure 210 of a cargo handling device according to another embodiment of the present invention. As in the previous embodiment, in this embodiment the cargo handling device comprises a vehicle having an upper section 112 that houses the main components of the device and a lower section having recesses 120 for housing boxes, on which the wheels 200 are arranged on the four sides of the recesses (only the wheels on one side are shown in Figure 14).
[0069] In this case, the frame structure 210 comprises two parallel panels that house the wheels 200 in between. The drive belt 212 is provided to transmit power from the motor housed in the upper part 112 of the vehicle to the wheels 200.
[0070] Referring further to Figures 15 and 16, the wheels 200 in this embodiment can be raised and lowered by moving the frame structure 210 relative to the upper part 112 of the vehicle. The frame structure 210 is mounted on the body 230 of the upper part 112 of the vehicle using rails 232. The rails 232 are fixed to the body 230 in a vertical orientation, and the frame structure 210 is slidably mounted on the rails 232.
[0071] The frame structure 210 is held in place by a pair of link mechanisms 240 extending between the panels. The bottom ends of the link mechanisms 240 are attached to the respective shafts 242 that span the gaps between the panels. The top ends of the link mechanisms 240 are rotatably mounted to threaded bosses 246, which are mounted on threaded horizontal drive shafts 244. The bosses 246 are slidably mounted to horizontal rails 248.
[0072] The drive shaft 244 is driven by a motor 250 using a drive belt (not shown). When the drive shaft 244 is rotated in a first direction, the upper end of the link mechanism 240 moves away from the frame structure 210 to push it downward, thereby lowering the wheel 200 onto the rail. When the drive shaft 244 is rotated in a second opposite direction, the upper end of the link mechanism 240 moves together with the frame structure 210 to pull it upward, lifting the wheel 200.
[0073] Although a single frame structure 210 with two wheels 200 is shown in Figures 14-16, it is understood that an identical frame structure 210 is provided on the opposite side of the vehicle. Both frame structures 210 are raised and lowered by a common motor, so that the four wheels 200 can be raised and lowered in harmony to control the engagement of the four wheels 200 with rails extending in a first direction across the frame. Although not shown in Figures 14-16, the vehicle also has another set of wheels positioned to engage with rails extending in a second vertical direction across the frame when the first set of wheels is raised.
[0074] It is understood that many different variations and improvements are possible. For example, the wheels of both sets may be powered by a single motor in an appropriate transmission configuration to direct the power to the wheels of the appropriate set. In other embodiments, one or more of the wheels may have an integrated motor or a motor positioned adjacent to the wheel. This example is shown in Figure 17.
[0075] Referring to Figure 17, this shows a cargo handling device 252 according to a further embodiment of the present invention. The device 252 has an external housing 254 which is shaped like a cube and has a plurality of wheels 256 mounted near the lower edge 258 of the housing 254. The wheels 256 are motor-mounted hub wheels, each of which has a motor built into the hub 260 of the wheel 256. The motors are used to drive each wheel 256 directly, and therefore this embodiment does not require a drive belt connecting the wheel and the drive motor.
[0076] In this example, the motor is powered by a battery located in the side wall 262 of the lower part 264 of the housing 254, adjacent to the container receiving space 266 of the device 252. Positioning the battery low in this manner has the advantage of lowering the center of gravity of the device 252, thereby improving the stability of the device 252 and enabling greater acceleration and deceleration. The device 252 is otherwise the same as in the previous embodiment, housing a similar mechanism for raising and lowering the wheels 256 and a similar lifting device for lifting the container into the container receiving space 266. The battery located in the side wall 262 is also used to power these components.
[0077] In any of the embodiments described above, the mechanism used to lift the container into the container receiving space can take any suitable form. For maximum stability and load capacity, it is desirable to provide four lifting cables, one cable arranged near each corner of the device, but different configurations may be used as needed, such as having fewer cables. Conveniently, all cables are wound and unwound using a single motor, but two or more motors may be used as needed.
[0078] Instead of a motor, the mechanism used to lift the wheels may be a linear actuator such as a linear motor or a hydraulic ram. Other means of powering the load handling device, such as using overhead power transmission or supplying power through rails on which the device runs, instead of using battery power, will be obvious to those skilled in the art.
[0079] It will be understood that features described in relation to one specific embodiment are interchangeable with features described in relation to other embodiments. For example, the motor-mounted hub wheel described in relation to Figure 17 may be used in any of the other embodiments, and / or the battery may be positioned lower and adjacent to the container receiving space in any of the embodiments to improve stability and enhance acceleration / deceleration. Other modifications and improvements not explicitly stated herein will also be apparent to the experienced reader. The invention described in the original claims of this application is listed below. [1] A storage system comprising a plurality of rails or tracks arranged in a grid pattern above a stack of a plurality of containers, wherein a loading handling device for lifting and moving the stacked plurality of containers, wherein the grid pattern comprises a plurality of grid spaces, each stack is located within the installation area of only a single grid space, and the loading handling device is configured to move laterally on the rails or tracks above the stack, A cargo handling device comprising a container receiving space positioned above the rail or track during use, and a lifting device positioned to lift containers from a stack into the container receiving space, A cargo handling device characterized in that, during use, the cargo handling device has an installation area that substantially occupies only a single grid space in the storage system. [2] The cargo handling device according to [1], further comprising: an upper section for housing components such as power components, control components, drive components, and / or lifting components; and a lower section including a container receiving space, wherein the lower section is positioned directly below the upper section. [3] The cargo handling device according to [1] or [2], further comprising an external housing that substantially encloses the container receiving space. [4] The cargo handling device according to [3], wherein the external housing is formed substantially as a cube. [5] The cargo handling device according to any one of [1] to [4], wherein the cargo handling device is configured to move in a first direction along a first set of rails or tracks and in a second direction along a second set of rails or tracks, wherein the second direction intersects the first direction. [6] A cargo handling device according to any one of [1] to [5], wherein the cargo handling device comprises a wheel assembly having a first set of wheels for engaging with the first set of rails or tracks to guide the movement of the device in a first direction, and a second set of wheels for engaging with the second set of rails or tracks to guide the movement of the device in a second direction. [7] The cargo handling device according to [6], wherein the wheels are arranged around the periphery of the container receiving space. [8] The cargo handling device according to [6] or [7], further comprising a frame structure for supporting the wheel of the wheel assembly. [9] The cargo handling device according to [8], wherein the frame structure is part of the external housing of the cargo handling device.
[10] The cargo handling device according to [8] or [9], wherein the frame structure is arranged around the container receiving space.
[11] A cargo handling device according to any one of [8] to
[10] , wherein the container receiving space is defined within the frame structure.
[12] The cargo handling device according to any one of [8] to
[11] , wherein the container receiving space is bounded at four sides by the frame structure.
[13] A cargo handling device according to any one of the [6] to
[12] , wherein one or more of the wheels are driven by a motor that is built into the wheel or positioned substantially adjacent to the wheel.
[14] A cargo handling device according to any one of the wheels, wherein one or more of the wheels are equipped with a wheel hub motor.
[15] A cargo handling device according to any one of [6] to
[14] , wherein one or more of the wheels are driven by one or more motors positioned above the container receiving space.
[16] The cargo handling device according to
[15] , further comprising drive transmission means arranged around the container receiving space for transmitting drive from the motor to the wheels.
[17] The cargo handling device according to
[16] , wherein the drive transmission means comprises a pulley and a drive belt.
[18] A cargo handling device according to any one of the wheels, wherein one or more of the wheels have a path that cooperates with a drive belt for driving the wheels.
[19] The cargo handling device according to
[18] , wherein the path comprises a series of teeth for engaging with a corresponding forming portion in the drive belt.
[20] A cargo handling device according to
[18] or
[19] , wherein the path is demarcated by a pair of tires.
[21] A cargo handling device according to any one of [6] to
[20] , further comprising means for selectively engaging and disengaging the first set of wheels with the first set of rails, and means for selectively engaging and disengaging the second set of wheels with the second set of rails.
[22] A load handling device according to any one of the [6] to
[21] , configured such that one or both sets of wheels are raised and lowered relative to the wheels of the other set.
[23] The cargo handling device according to
[22] , further comprising one or more wheel lifting devices positioned above the container receiving space and arranged to lift the wheels.
[24] The cargo handling device according to
[23] , wherein the wheel lifting device or each wheel lifting device is configured to lift the wheel via a link mechanism located below the cargo handling device adjacent to the container receiving space.
[25] A cargo handling device according to any one of [1] to
[24] , wherein the lifting device comprises a gripping device configured to grip the container from above.
[26] The cargo handling device according to
[25] , further comprising a lifting mechanism configured to raise and lower the gripping device relative to the container receiving space.
[27] The cargo handling device according to
[26] , wherein the lifting mechanism is positioned above the container receiving space.
[28] The cargo handling device according to
[27] , wherein the lifting mechanism comprises a motor.
[29] The cargo handling device according to
[28] , wherein the lifting mechanism further comprises a hoisting machine arranged to be driven by the motor.
[30] A cargo handling device according to any one of
[25] to
[29] , wherein the gripping device is suspended from a cable which can extend from and retract from the cargo handling device in order to move the gripping device vertically.
[31] A cargo handling device according to any one of
[25] to
[28] , wherein the lifting device comprises a pair of lifting arms positioned on either side of the container receiving space, and the gripping device is mounted on the ends of the arms, and the arms are configured to extend and retract in order to move the gripping device vertically.
[32] The cargo handling device according to any one of
[25] to
[31] , wherein the center of mass is located directly above the gripping device when the gripping device is lowered downward into the container receiving space.
[33] The cargo handling device according to any one of [1] to
[32] , wherein the cargo handling device is a self-propelled robotic vehicle.
[34] A cargo handling device according to any one of [1] to
[33] , further comprising one or more batteries for supplying power to the components of the device, wherein the batteries are located in the lower part of the device adjacent to the container receiving space.
[35] A cargo handling device according to
[34] , wherein the batteries are located within the side wall of the device.
[36] A first set of parallel rails or tracks, and a second set of parallel rails or tracks extending across the first set in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces, A plurality of stacks of containers positioned below the rail, each arranged so as to occupy the installation area of a single grid space, A cargo handling device according to any one of [1] to
[35] , which is arranged to move laterally on the rail above the stack, wherein the cargo handling device comprises a container receiving space positioned above the rail, and a lifting device arranged to lift a single container from the stack into the container receiving space, In a storage system equipped with, A storage system characterized in that the cargo handling device has an installation area that substantially occupies only a single grid space in the storage system.
[37] The storage system according to
[36] , wherein the storage system comprises a plurality of cargo handling devices as described in any one of [1] to
[35] .
[38] The storage system according to
[36] or
[37] , further comprising one or more load handling devices that can lift multiple containers out of a stack in a single run.
[39] A storage system according to any one of
[36] to
[38] , further comprising one or more port locations from which a plurality of containers can be removed from and / or added to the storage system.
[40] The storage system according to
[39] , wherein the cargo handling device is configured to transport the target container from the stack to the port location.
[41] The storage system according to any one of
[36] to
[40] , wherein the container is a box without a top.
[42] The storage system according to any one of
[36] to
[41] , wherein the containers are arranged to be connected or engaged with one another in the vertical direction when stacked.
Claims
1. A cargo handling device (100) for use in a storage system comprising a grid frame for accommodating a stack of multiple containers (12), The cargo handling device (100) is suitable for placement above a stack of containers (12), and the cargo handling device (100) can lift a container (106) from the stack and move the container (106) laterally to another location. Herein, the cargo handling device (100) comprises two sets of wheels (116, 118) for supporting the cargo handling device (100) on the rail above the stack, and the two sets of wheels are A first set of wheels (116) for engaging with a first set of rails (22a) to guide the movement of the device in a first direction (X), wherein the first set of wheels comprises two pairs of wheels. The device comprises a second set of wheels (118) for engaging with a second set of rails (22b) to guide the movement of the device in a second direction (Y), wherein the second set of wheels comprises two sets of wheels. Here, the wheels (116, 118) of one or both sets are configured to rise and fall relative to the wheels (116, 118) of the other set. The cargo handling device includes a container receiving space (120) from which the container can be lifted so that the load of the container is suspended between a pair of wheels on each side of the cargo handling device. The container receiving space is located beneath the vehicle module (112) which houses components such as power components, control components, drive components, and lifting components. Herein, the vehicle module (112) is characterized by housing a battery for supplying power to a motor, a control device, a sensor, and other components, in a cargo handling device.
2. The cargo handling device according to claim 1, wherein the cargo handling device comprises a crane device (104) for lifting the container (106) into the container receiving space.
3. The cargo handling device according to claim 2, wherein the crane device (104) includes one or more motors for lifting the container, and the or each motor is housed in the vehicle module (112).
4. The cargo handling device according to claim 3, wherein the crane device (104) includes a gripping device (110) configured to grip the container from above.
5. A storage system comprising a frame for accommodating a plurality of stacks (12) of containers (106), and one or more of the cargo handling devices (100) according to any one of claims 1 to 4, positioned above the stack of containers.