Automated storage system

Abstract

Described and claimed is an automated storage system for stacks of storage units. The automated storage system comprises a storage rack, one or more shuttles and a flipper device. The storage rack is made up of storage channels which each define a plurality of storage positions. The shuttle is able to transport stacks of storage units to and from storage positions in the storage channels. In one of the storage channels a flipper device is provided which is able to change the order of storage units in a stack that was placed on a unloading position and create a stack with a changed order of storage units on a loading position. Further, a method for operating such an automated storage system is described and claimed.

Description

[0001] Title: Automated storage system

[0002] Description

[0003]

[0001] The present invention is directed to an automated storage system for stacks of storage units. The invention is further directed to a method for operating an automated storage system.

[0004] [2] Dedicated automated storage systems are available for products or goods that can be stored in standard-sized totes or bins. Such totes or bins may also generally be referred to as standard storage units and the automated storage system may also be referred to as an automated storage and retrieval system or an automated storage and order fulfillment system.

[0005] [3] An exemplary automated storage system comprises a plurality of storage channels extending in parallel to a lateral direction. Each of the storage channels branches off one or more main aisles extending in a longitudinal direction, i.e., perpendicular to the lateral direction. The storage channels provide two or more sequentially arranged storage positions. A width of the storage channels corresponds to a width of the storage units. Shuttles automatically transport the storage units through the storage channels and the main aisles.

[0006] [4] If comparatively small products or articles are to be stored in the automated storage system or only a small number of the same products, a standard-sized storage unit would only be partially filled with products. However, since a partially filled storage unit takes up the same space as a full storage unit, using standard-sized storage units for comparatively small products or small numbers of a product can be inefficient. [5] To increase the efficiency of the storage system, larger standardsized storage units may be replaced with smaller storage units. For example, one standard-sized storage unit may be replaced with a stack of two or more small storage units which have the same width and depth as the standard-sized storage units but a reduced height. For example, the height of a small storage unit may be about 1 / 3 of the height of the standard-sized storage unit. A stack of three small storage units would thus have approximately the same dimensions as a standard-sized storage unit. Using such stacks of small storage units increases the storage system efficiency as small products and / or small numbers of a product can be stored in stacks of small storage units which reduces the empty space in the storage racks as compared to storing these products in standard-sized storage units.

[0007] [6] Stacking multiple small multiple storage units restricts the accessibility to goods that are not located in the uppermost storage unit of a stack. In order to access these goods, either the corresponding storage unit needs to be removed from the stack or the order of storage units in the stack needs to be changed so that the desired goods are located in the top storage unit.

[0008] [7] In view of the above it is an object of the present invention to provide an improved automated storage system as well as an improved method for operating the automated storage systems. In particular, the system and method are intended to facilitate handling of stacks of storage units.

[0009] [8] The object is solved by an automated storage system and a method for operating an automated storage system according to the respective independent claims. Preferred embodiments of the system and the method are the subject matter of the respective dependent claims.

[0010] [9] In a first aspect, an automated storage system for stacks of storage units is provided. The automated storage system comprises a storage rack defining a plurality of storage channels. Each storage channel of the plurality of storage channels extends parallel to a lateral direction and comprises two or more storage positions for stacks of storage units. The two or more storage positions are arranged consecutively in a direction extending parallel to the lateral direction. The system further comprises at least one shuttle for transporting stacks of storage units. Each shuttle is configured to move parallel to the lateral direction through each storage channel of the plurality of storage channels. Each shuttle is further configured for unloading a stack of storage units at an unloading position of the two or more storage positions of a flipper channel of the plurality of storage channels and retrieving a stack of storage units located at a loading position of the two or more storage positions of the flipper channel. The system further comprises a flipper device configured for forming a flipped stack of storage units at the loading position by at least lifting one or more storage units from a stack of storage units located at the unloading position so that at least one storage unit of the stack of storage units remains at the unloading position, placing the lifted one or more storage units at a flipper position of the two or more storage positions, lifting one or more of the remaining storage units of the stack of storage units from the unloading position and placing the lifted one or more remaining storage units on top of the storage units which have previously been placed at the flipper position.

[0011]

[0010] In other words, the automated storage system comprises at least a storage rack for stacks of storage units, one or more shuttles for moving stacks of storage units to and from storage positions in the storage rack and a flipper device for rearranging the order of storage units in a stack of storage units. Subsequently, a stack of storage units may also simply be referred to as a stack.

[0012]

[0011] The storage units may also be referred to as totes or units or boxes and are used for holding products that shall be stored in the storage arrangement. Preferably, all storage units have identical width and depth, i.e., they cover the same storage area in the storage rack and could be said to have the same footprint. Further, the storage units are stackable. This requires, for example, each storage unit to be sufficiently rigid to support one or more additional storage units including articles stored therein. Also, the storage units are preferably shaped or formed so that two stacked storage units are interconnected to prevent stacks of storage units from falling apart during transport. Furthermore, all storage units in a stack of storage units are preferably of identical height. However, it is also possible that storage units of different heights are included in a stack.

[0013]

[0012] As previously described, a stack of, for example, three or five stacked small storage units could have the same height as one standardsized storage unit. While such a relationship of stacked small storage units and standard-sized storage units is preferred, it is not a requirement. Also, there is no need for the system to include any storage units of different sizes, but these may very well be present in a system implementing the subsequently discussed features. Subsequently when discussing the general operation of the automated storage rack, it is understood that a stack of storage units may also be formed by a single storage unit. However, insofar operation, structure and application of the flipper device is discussed, a stack of storage units comprises at least two storage units.

[0014]

[0013] The storage rack has a plurality of lanes or channels. A channel can be accessed from at least one end by a shuttle. An end through which a shuttle can drive into or out of a channel may also be referred to as an open end. An end of a channel through which no shuttle can drive into or out of a channel may also be referred to as a closed end. Hence, each channel has one or two open ends and one or no closed end.

[0015]

[0014] In each channel two or more stacks of storage units may be placed sequentially, i.e., one after the other. To this end, two or more consecutive storage positions are provided in each channel. For example, each channel in a storage rack may hold between two and five stacks of storage units which are placed in the storage positions. Only those stacks of storage units which are directly adjacent to an open end can be directly removed from a channel via the respective open end. In case one or more stacks of storage units are disposed between a stack of storage units that shall be removed through an open end and the open end, these stacks of storage units need to be removed first.

[0016]

[0015] The stacks of storage units are transported through the storage rack, for example, between two storage positions, between a storage position and a commissioning unit or between a storage position and an unloading position associated with a flipper device using shuttles. The shuttles are preferably fully automated although this is not a necessary requirement. For a shuttle to be able to transport a stack of storage units to a certain storage position, it has to be able to move parallel to the lateral direction through the storage channel. At a storage position where a stack of storage units is located, the shuttle may load the stack of storage units onto the shuttle, for example, by lifting it upwards from support means. The shuttle then drives, for example, to a second storage position where it unloads the stack of storage units. Unloading the storage channel can, for example, be achieved by lowering the stack of storage units onto a support means provided at the storage position.

[0016] For changing the order of the storage units in a stack, the shuttles may unload a stack of storage units at storage position which is also referred to as an unloading position and load a stack of storage units at another storage position which is also referred to as a loading position. The unloading position and the loading position are located in the same storage channel of the storage rack. Since this is the storage channel where the order of the storage units in a stack is altered or changed, i.e., the stack of storage units is flipped, this specific storage channel is also referred to as a flipper channel. Thus, the loading and unloading position are located in the flipper channel and consequently aligned along an axis extending parallel to the lateral direction. The flipper channel has preferably a similar if not identical width perpendicular to the lateral direction as all other storage channels.

[0017]

[0017] In the flipper channel a flipper device is provided which may, for example, be formed as an overhead crane or bridge crane. The flipper device needs to be able to lift one or more storage units from the top of a stack of storage units located at the unloading position. However, at least one storage unit remains at the original unloading position. The lifted one or more storage units are moved by flipper device to a flipper position. The flipper position may coincide with the loading position. However, in other exemplary embodiments the flipper position may be a separate storage position in the flipper channel.

[0018]

[0018] After placing the storage units lifted from the top of the stack at the flipper position, the flipper device lifts at least one remaining storage unit from the unloading position and moves the at least one lifted remaining storage unit also to the flipper position where it is positioned on top of those storage units which have previously been placed in the flipper position. In case the flipper position coincides with the loading position, these steps may be sufficient to form a flipped stack at the loading position. In other embodiments, the storage units placed intermittently at the flipper position will hove to be moved to the loading position to finally form the flipped stack.

[0019]

[0019] Hence, the flipper device is configured for changing the order of the storage units in a stack of storage units. For example, a storage unit which was previously in the middle or at the bottom of a stack may be placed at the top of the stack. Likewise, a storage unit that was previously at the top of the stack may be moved to a center position or the bottom of the stack.

[0020]

[0020] The flipper device advantageously allows changing the order of storage units in a stack of storage units. This facilitates access to products or goods stored in a storage unit that was previously arranged in a center of a stack. Further advantageously, the flipper device is fully integrated in one of the channels of a storage rack. This simplifies the integration of a flipper device in an existing storage rack as the flipper position, as the loading position and the unloading position are interpreted as regular storage positions by the shuttles for loading and unloading stacks of storage units.

[0021]

[0021] Operation of the automated storage system can be controlled in various ways. For example, a centralized control system can be provided on a server system or a distributed computing system which fully controls operation of all entities, i.e., the one or more shuttles and the flipper device. For example, the central control system determines which shuttle moves currently at what speed in which direction along and instructs the flipper device to lift of a certain number of storage units from the unloading position and move them to the flipper position and / or the loading position. Alternatively, distributed control systems can be used where each entity in the automated storage system receives more generic instructions and carries these instructions out on its own. For example, a shuttle could receive instructions to transport a stack of storage units from storage position A to storage position B but has to determine itself which route to take and at which speed the stack is transported. Similarly, the flipper device could only be instructed to move storage unit C from a stack of storage units to the top position but needs to implement the necessary steps by itself. Also, mixed control systems can be used where different levels of instructions can be provided from an internal or external control system.

[0022]

[0022] In a preferred embodiment, the loading position is located directly adjacent to the unloading position. In other words, the storage positions which are used for unloading a stack to be flipped and for loading the flipped stack of storage units are next to each other. This results in a very compact design of the flipper device as only two storage positions need to be reserved. Additional storage positions in the flipper channel can be used for storage of stacks of storage units unless they are required for a dedicated flipper position. In case the same shuttle is used to unload a stack of storage units at the unloading position and retrieve the flipped stack of storage units at the loading position, the shuttle only needs to drive the shortest possible distance to collect the flipped stack. Also, the distance the flipper device needs to move the storage units while flipping the stack is minimized, in particular, if the flipper position corresponds to the loading position.

[0023]

[0023] In a preferred embodiment, the flipper channel extends between a first end and a second end. The loading position is arranged between the first end and the unloading position. The first shuttle is configured for retrieving the flipped stack of storage units placed at the loading position by the flipper device and transporting the flipped stack out of the flipper channel via the first end of the flipper channel.

[0024] In other words, in the preferred embodiment a shuttle is able to retrieve a flipped stack of storage units at the loading position and transport the flipped stack of storage units out of the flipper channel through a first end thereof. The loading position is closer to the first end than the unloading position where the stack of storage units was originally unloaded by a shuttle before it was flipped. In particular, in case the same shuttle is used to drop off the stack of storage units and retrieve the flipped stack of storage units, positioning the loading position closer to the first end is advantageous as the transport distance and consequently also the transport time of the flipped stack are reduced.

[0024]

[0025] In a preferred embodiment, a first shuttle is configured for entering the flipper channel with a stack of storage units through the first end or for entering the flipper channel with a stack of storage units through the second end and unloading the stack of storage units at the unloading position.

[0025]

[0026] Thus, in case the first shuttle enters the flipper channel through the first end, the first shuttle needs to move past the loading position for unloading the storage units at the unloading position and moving in the opposite direction to the loading position after the stack of storage units has been unloaded. Hence, in the preferred embodiment the same first shuttle is configured for dropping off the stack of storage units to be flipped and retrieving the flipped stack of storage units. Given the positioning of the unloading position and the loading position, the shuttle changes is driving direction for retrieving the stack at the second storage position. Hence, advantageously the shuttle changes its driving direction while it is empty and also shortens the distance to the intended exit of the flipper channel while the stack of storage units is being flipped and the shuttle anyhow needs to wait.

[0027] In case the first shuttle enters the flipper channel with a stack of storage units through the second end, the stack of storage units may be unloaded at the unloading position before moving to the loading position without having to change the driving direction and without passing the loading position on the way to the unloading position.

[0026]

[0028] In a preferred embodiment, the flipper position corresponds to the loading position so that the flipped stack of storage units is formed at the flipper position. Hence, in the preferred embodiment the first storage units removed from the top of the stack to be flipped are directly placed at the loading position by the flipper device and form the bottom of the flipped stack of storage units.

[0027]

[0029] In another embodiment, the loading position corresponds to the unloading position. The flipper device is configured for moving storage units moved to the flipper position back to the combined loading and unloading position to form the flipped stack of storage units at the combined loading and unloading position. Thus, in this embodiment the flipper position is a different position as the loading position. The flipper position thus essentially forms an intermediate storage position where storage units are temporarily placed while a stack is flipped.

[0028]

[0030] Furthermore, in an exemplary preferred embodiment, the flipper position, the loading position and the unloading position are all separate storage positions, i.e., the flipper device has in this embodiment at least three storage positions for flipping a stack of storage unit. While it is preferred that the flipper device requires only two storage position for flipping stacks of storage units to minimize the space consumption of the flipper device, other embodiments may facilitate the use of simpler flipper devices which can only lift a limited number of storage units.

[0031] In general, it is noted that the flipper position, the loading position and the unloading position are not necessarily permanently assigned to a certain storage position in the flipper channel that can be reached by the flipper device. In particular in embodiments where different numbers of storage units may form a stack, it may be necessary to use a separate flipper position for some stacks, whereas no separate flipper position is required for other stacks. For example, for a flipper device that is configured to lift two storage units of a stack, at stack of three storage units may be flipped using an unloading position and a loading position that corresponds to a flipper position. Using the same flipper device, flipping a stack of four storage units requires a separate flipper position, but the same storage position could be used as loading and unloading position. Since from the perspective of the shuttles the loading and unloading positions can be treated as any other storage position, the system can advantageously redesignate storage positions as need at any time.

[0029]

[0032] However, it is pointed out that in other embodiments the flipper position, the unloading position and the loading position may be permanently assigned to given storage positions.

[0030]

[0033] In a preferred embodiment, each storage channel comprises a pair of support rails for supporting storage units. The support rails extend parallel to the lateral direction on opposing sides of the storage channel. Each storage channel is configured so that each of the at least one shuttle can move below the support rail parallel to the lateral direction through the storage channel. The at least one shuttle is configured for lifting a stack of storage units above the support rails for transporting the stack of storage units.

[0031]

[0034] The support rails may, for example, be formed as C-shaped beams or supports that extend on either side of the storage channels. The stacks of storage units rest on top of the support rails, i.e., on the upper arm of the C-shaped beam. The shuttles drive through the storage channels below the storage units and may, for example, use the lower arms of the C as rails. This allows the shuttles to move underneath a stack without having to move the stack. The stacks may be loaded onto a shuttle by lifting them upwards and keeping them in this lifted position. For unloading the stacks, they simply have to be lowered onto the support rails. To this end, the shuttles may use a vertically movable lifting device that can lift a stack of storage units upwards from a support rail.

[0032]

[0035] The system preferably further comprises a second shuttle for transporting stacks of storage units. The second shuttle is configured for retrieving a flipped stack of storage units located at the loading position. The flipped stack of storage units comprises storage units which have previously been placed at the at the unloading position by a first shuttle. Hence, in the preferred embodiment different shuttles are used for unloading the stack to be flipped at the unloading position and for loading the flipped stack at the loading position. This has the advantage that during the flipping operation no shuttle has to wait but can instead transport other storage units.

[0033]

[0036] In a further preferred embodiment, each storage unit in a stack of storage units to be placed at the unloading position comprises two opposing sidewalls. Each sidewall comprises at least one projection. The flipper device comprises a gripping unit which is configured for engaging with the at least one projection on each sidewall of a storage unit for lifting the storage unit and any storage unit located on top of the storage unit from a stack of storage units. Hence, in the preferred embodiment the storage units have indentations which are used by a gripping unit of the flipper device for lifting the storage units. These indentations are shaped so that the gripping device does not have to compress the storage units for lifting them upwards. Rather, downward facing surfaces formed in the indentations rest on the gripping unit when the storage units are moved by the flipper device.

[0034]

[0037] Preferably, the storage system comprises a first main aisle. The flipper channel extends perpendicular to and away from the first main aisle. Further preferably, the storage system comprises a second main aisle extending parallel to the first main aisle. The flipper channel extends between the first main aisle and the second main aisle.

[0035]

[0038] Hence, in the preferred embodiment additional aisles or transport channels are provided in the storage rack which allow the shuttles to move in directions extending perpendicular to the lateral direction. The one or more main aisles are in particular provided for interconnecting the storage channels. The storage channels extend parallel to the lateral direction and thus perpendicular to the main aisle. The main aisle can be said to extend parallel to a longitudinal direction.

[0036]

[0039] In a second aspect the problem underlying the present invention is solved by a method for operating an automated storage system according to any of the preceding embodiment. As part of the method, a stack of storage units comprising at least two storage units is transported with a first shuttle by moving parallel to the lateral direction through the flipper channel. Further, the stack of storage units is unloaded from the first shuttle at the unloading position. A flipped stack of storage units is formed at the loading position by at least lifting with the flipper device one or more storage units from the stack of storage units located at the unloading position so that at least one storage unit of the stack of storage units remains at the unloading position, placing with the flipper device the lifted one or more storage units at the flipper position, lifting with the flipper device one or more of the at least one remaining storage unit of the stack of storage units from the unloading position, and placing the lifted one or more remaining storage units on top of the storage units which have previously been placed at the flipper position. Finally, the flipped stack of storage units located at the loading position is retrieved with a shuttle.

[0037]

[0040] Preferably, the flipper channel extends between a first end and a second end, and the loading position is arranged between the first end and the unloading position. The first shuttle retrieves the flipped stack of storage units from the loading position and transports the flipped stack out of the flipper channel via the first end of the flipper channel. Further preferably, the first shuttle enters the flipper channel with the stack of storage units through the first end or through the second end.

[0038]

[0041] It is further preferred to retrieve the flipped stack of storage units located at the loading position with a second shuttle.

[0039]

[0042] In a preferred embodiment, the flipper position corresponds to the loading position so that the flipped stack of storage units is formed by the flipper device at the flipper position.

[0040]

[0043] Alternatively, the loading position may correspond to the unloading position. In this embodiment, the flipper device moves storage units from the flipper position back to the combined loading and unloading position to form the flipped stack of storage units at the combined loading and unloading position.

[0041]

[0044] Details of the respective embodiments of a method have already been described with regard to the exemplary embodiments of the automated storage system that is used for implementing the method. Therefore, in order to avoid unnecessary repetitions, reference is made to the above description of the system that also applies to the method. Consequently, the advantages of the preferred embodiments of the method correspond to the advantages of the system used for implementing the method.

[0042]

[0045] Further details of the automated storage system and the method for operating an automated storage system will be described with reference to the exemplary embodiments shown in the drawings, wherein

[0043] Figure 1 shows a top view of an exemplary embodiment of an automated storage system for stacks of storage units,

[0044] Figure 2 shows a side view of an exemplary embodiment of a flipper device for an automated storage system,

[0045] Figure 3 shows a perspective view of the exemplary embodiment of figure 2,

[0046] Figure 4 shows a second perspective view of the exemplary embodiment of figure 2,

[0047] Figure 5 shows a front view of the exemplary embodiment of figure 2, and

[0048] Figure 6 shows a flow chart of an exemplary embodiment of a method for operating an automated storage system for stacks of storage units.

[0049]

[0046] Figure 1 shows a schematic top view of an exemplary embodiment of an automated storage system 1 for storing stacks 3 of storage units 5. In figure 1 a stack 3 of storage units is depicted using three rectangles arranged one inside the other. The three rectangles symbolize that each stack comprises a plurality of storage units 5. However, these storage units 5 have identical dimensions in a horizontal place and the different size of the rectangles has only been chosen to symbolize the stack 3. Only some of the storage units 5 in the stacks 3 have been labeled with the reference numeral 5 to avoid obstructing the figure with too many reference numerals and connecting lines.

[0050]

[0047] In the exemplary embodiment each stack may comprise up to five identical bins or totes 5 which are also referred to as storage units 5. However, the stack 3 may only comprise four storage units5, three storage units 5 or even only two storage units 5. Furthermore, the storage system 1 is also capable of handling only single storage units 5 which are shown in various storage positions 7 across the schematic representation in figure 1 .

[0051]

[0048] The storage positions 7 are shown in figure 1 as square boxes drawn in dashed lines. In order to keep figure 1 intelligible, only some of the storage positions 7 have been labeled with reference numerals.

[0052]

[0049] In the exemplary embodiment of a storage system 1 shown in figure 1 , a storage rack 9 defines storage channels 1 1 out of which five storage channels 1 1 a, 1 1 b, 1 1 c, 1 1 d, 1 1 e are shown in figure 1 . In the storage channels 1 l a-1 l e the storage positions 7 are arranged sequentially between a first end 13 and a second end 15 of the storage channels 1 1 a- 1 1 e. Note that in figure 1 only for the center storage channel 1 1 c the first end 13 and the second end 15 have been designated with reference numerals to avoid obfuscating the figure with too many reference numerals. At the respective first end 13, the storage channels 1 l a-1 l e merge into a first main aisle 17a. The first main aisle 17a extends parallel to a longitudinal and parallel to a second main aisle 17b. At the respective second end 15 the storage channels 1 1 a-1 1 e merge into the second main aisle 17b. Hence, the storage channels 1 l a-1 l e extends between the first and the second main aisle 17a, 17b.

[0050] The storage channels 1 1 a-1 1 e extend perpendicular to the main aisles 17a, 17b and, thus, the longitudinal direction 19, i.e., parallel to a lateral direction 21 . Within each storage channel five storage positions 7 are arranged sequentially or consecutively so that only the outer storage positions 7 can be directly accessed from one of the main aisles 17a, 17b whereas the three center storage positions 7 can only be accessed by moving at least past one of the outer storage positions 7. Within each storage channel 1 l a-1 l e two support rails 23 are provided. On the support rails 23 the storage positions 7 are defined. The storage units 5 as well as the stacks 3 of storage units 5 are lowered onto the support rails 23 when they are placed in the storage rack 9. Only in the top channel 1 1 a in figure 1 the support rails 23 are designated with reference numerals.

[0053]

[0051] Furthermore, the system 1 comprises a plurality of shuttles 25 out of which three are shown in figure 1 . The shuttles 25 are able to move parallel to the longitudinal direction 19 through the main aisles 17a, 17b and parallel to the lateral direction 21 through the storage channels 1 1 a-1 1 e. In this exemplary embodiment the shuttles 25 move below the storage position 7. This allows an empty shuttle to drive underneath a storage position on which a stack 3 of storage units 5 has been placed. For example, a shuttle 25 may move from the first main aisle 17a through the second storage channel 1 1 b to the second main aisle 17b even though three of the five storage positions 7 in the storage channel 1 1 b are in use.

[0054]

[0052] The shuttles 25 are configured to lift a stack 3 or an individual storage unit 5 upwards from a storage position 7 for transporting them through the storage system 1. In order to drop off a storage unit 5 or a stack 3 of the storage units 5 at a storage position 7, the shuttle 25 lowers the respective storage unit 5 or storage units 5 onto the support rails 23. Once a support means provided on a shuttle 25 has been fully retracted, the shuttle 25 can drive to another storage position 7 for retrieving another stack 3 of storage units 5.

[0053] The automated storage system 1 shown in figure 5 further comprises a flipper device 27 which has been installed in a transport channel 1 1 d. The transport channel 1 1 d in which the flipper device 27 is arranged may also be referred to as a flipper channel 29. The flipper device 27 covers two storage positions 7 which are designated as a loading position 31 and an unloading position 33. Notably, the remaining storage positions 7 in the flipper channel 29 can in principle be used in the same way as any other storage position 7 although this would either limit access to the flipper device 27 or access to these storage positions 7 would be limited by operations of the flipper device 27.

[0055]

[0054] As will be explained in more detail with reference to the subsequent figures showing an exemplary embodiment of a flipper device 27 as well as a method for operating the automated storage system 1 , the flipper device 27 is provided for changing the order of the storage units 5 in a stack of storage units 3 that has been placed at the unloading position 33. To this end, the flipper device 27 comprises a gripping means 35 that is configured for lifting one or more storage units 5 from a stack 3. The flipper device is able to move the lifted storage units 5 from one storage position 7 to another. For example, one or more storage units 5 may be shifted from the unloading position 33 to the flipper position 37. The latter coincides in the exemplary embodiment shown in figure 1 with the loading position 31 .

[0056]

[0055] In figure 1 , one storage unit 5 has been moved from the stack 3 initially placed at the unloading position 33 to the flipper position 37. In a subsequent step the flipper device 27 could now lift the remaining storage units 5 from the unloading position 33 onto the storage unit 5 that has already been placed at the flipper position 37. Thereby, the order of the storage units 5 in the stack 3 originally placed at the unloading position 33 would be changed in the new stack 3 that is formed at the flipper position 37 / loading position 31.

[0056] As can be seen in figure 1 , a shuttle 25 is already waiting at the loading position 31 for retrieving the flipped stack 3 once the flipping operation has been completed. Note that the flipper device 27 shown in figure 1 and also as shown in figures 2 to 4 could also be used for splitting up a stack 3 of storage units 5 by moving some of the storage units 5 to the loading position 31 while leaving the remaining storage units 5 at the unloading position 33. Thereby, entire stacks 3 can be separated. Furthermore, if new storage units are placed at the unloading position 33, these new storage units 5 could be added on top of a storage unit 5 or a stack 3 of the storage units 5 already placed at the loading position 31 to form new stacks 3.

[0057]

[0057] The automatic storage system 1 also comprises a control unit 39 which is represented in figure 1 by a simple box. The control unit or control system 39 may take various forms such as a centralized control system, a decentralized control system or combinations thereof.

[0058]

[0058] Furthermore, the automated storage system 1 comprises a charging device (not shown) integrated below the support rail 23 at the loading position 31 . The charging device can charge the batteries of a shuttle 25 while the shuttle 25 is waiting for a stack 3 of storage units 5 to be flipped. Additionally or alternatively, a charging device may be installed below the support rail 23 at the unloading position 33.

[0059]

[0059] The automated storage system 1 as shown in figure 1 has the advantage that a flipper device 27 which can rearrange the storage units 5 in a stack 3 is fully integrated into the storage rack 9. It does, in particular, not take up more space than two regular storage positions 7. Furthermore, the shuttles 25 provided for transporting storage units 5 and stacks 3 through the storage system can without further adaptation be used for transporting stacks 3 to the unloading position 33 of the flipper device 27 and retrieving flipped stacks 3 from the loading position 31 since the loading and unloading position 31 , 33 are regular storage positions 7 such as any other storage position 7 in the storage rack 9.

[0060]

[0060] It should be further pointed out that figure 1 is a schematic drawing and the dimensions of the parts of the storage system 1 are not shown to scale. For example, the boxes depicting the storage rack 9 may be over dimensioned as compared to the other parts.

[0061]

[0061] Figures 2 to 5 show an exemplary embodiment of a flipper device 27. The flipper device 27 has been integrated into the storage rack 9 with two support rails 23 at the bottom of the storage channel 1 1 . Three storage units 5 are arranged on an upper edge or upper leg of the C-shaped storage rails. The flipper device 27 covers two storage positions 7. One of the storage positions 7 is used for unloading a stack 3 of storage units to be flipped. This storage position 7 is referred to as the unloading position 33. The second storage position 7 covered by the flipper device 27 is used for loading the flipped stack 3 of storage units. It is, therefore, referred to as the loading position 31 where the flipped stack 3 is retrieved by a shuttle 25.

[0062]

[0062] The flipper device 27 further comprises a bridge crane 41 with gripping means 35 that can move parallel to the lateral direction 21 on crane rails 43. The gripping means 35 is further able to move in a vertical direction 45 for lifting storage units 5 upwards at one storage position 7 and moving them in the lateral direction 21 to another storage position 7 where they are lowered back either onto the support rail 23 or another storage unit 5 by moving the gripping means downward parallel to the vertical direction 45.

[0063] In figures 2 to 5, a shuttle (not shown) originally placed a stack 3 of three storage units 5 at the unloading position 33. The gripping means 35 on the flipper device 27 has already been used to move two of the storage units 5 to the loading position 31 which corresponds in the embodiment of figures 2 to 5 to the flipper position 37. Subsequently, the gripping means 35 will release the two storage units 5 now located at the loading position 31 and fetch the storage unit 5 remaining at the unloading position 33. The remaining storage unit 5 is then placed on top of the storage units 5 previously placed at the loading position 31 to form a flipped stack 3 of storage units 5. In the flipped stack 3 the storage unit 5 which was originally at the bottom of the stack 3 when it was unloaded at the unloading position 33 is now on top of the stack 3 and can be easily accessed, for example, at a dispenser or commissioning unit (not shown).

[0063]

[0064] Figures 2 to 5 highlight several advantages of the automated storage system 1 and the flipper device 27 used therein. The flipper device 27 is fully integrated into a storage channel 1 1 and thus does not take up any space beyond the two storage positions 31 , 33 required for loading and unloading the stack 3 and the flipped stack 3. Furthermore, in figures 2 to 5 it is also visible that the automated storage system 1 may comprise multiple layers of storage channels 1 1 each defined by two C-shaped support rails. Here, upper support rails 47 are shown on which the next level of storage positions 7 may be defined. Thus, the flipper device 27 is sufficiently compact that it even fits within in a multi-layered automated storage system 1 .

[0064]

[0065] Note that the flipper device 27 may also be designed to take up storage positions in two levels of a storage system 1 . The storage positions in the lower level receive the storage units 5, while the storage positions in the upper level are blocked by the bridge crane 41 and used for moving the storage units 5 between the storage positions in the lower level.

[0066] The gripping means 35 shown in figures 2 to 5 is advantageously configured to grip storage units 5 that engage with indentations 49 formed at the outer walls 51 of the storage units. In the embodiment shown in figures 2 to 5, the gripping means 35 engages with indentations formed at walls 51 which extends perpendicular to the lateral direction 21 . The gripping means 35 is preferably formed so that no pressure acts on the storage units 5 in the lateral direction 21. Rather, the gripping means 35 engages with upper edges of the indentations 49 to lift the storage units 5 so that products located in the storage units 5 are not subject to any outside compressive forces when lifted upwards by the flipper device 27.

[0065]

[0067] The flipper device 27 shown in figures 2 to 5 has been integrated at a closed end 53 of a storage channel 1 1 / flipper channel 29. Thus, a shuttle 25 carrying a stack 3 of storage units 5 may only enter the flipper device 27 from the opposing end of the flipper channel 29 which is, however, not shown in figures 2 to 5. At the closed end 53 an optional door 55 is provided which restricts access of an operator or user of the system 1 to the flipper device 27. The door 55 is shown in Figure 4 but has been omitted in Figures 2, 3, and 5 to keep the view on the parts of the flipper device 27 unobstructed. In case the entire storage system 1 is surrounded by a fence (not shown), the door 55 can be omitted.

[0066]

[0068] Finally, with reference to figure 6 an exemplary embodiment of a method for operating an automated storage system 1 will be described. Figure 6 is a schematic flow diagram.

[0067]

[0069] In a first step 57 a shuttle 25 carries a stack 3 of storage units 5 to an unloading position 33 in a flipper channel 29. The shuttle 25 enters the flipper channel 29 through a first end 13 which is also the end through which the shuttle 25 will leave the flipper channel 29 after collecting the flipped stack 3. Therefore, on its way to the unloading position 33 the shuttle 25 moves past the loading position 31 where the flipped stack 3 will be formed by the flipper device 27.

[0068]

[0070] In a second step 59 the shuttle 25 unloads the stack 3 at the unloading position 33. For example, the shuttle 25 may lower a lifting device so that the bottom storage unit 5 in the stack 3 comes to rest at the upper arm of the support rails 23. The shuttle 25 moves through the storage channel on the lower arm of the C-shaped support rail 23. Thus, the support rails 23 not only define the storage positions 7 but also serve as rails for the shuttles 25 when they move through the storage channels 1 l a- 1 l e.

[0069]

[0071] In a third step 61 the shuttle 25 changes its direction and drives from the unloading position 33 to the loading position 31 . In a fourth step 63 the gripping means 35 of the flipper device 27 grips one or more of the storage units 5 of the stack 3 that has been placed at the unloading position 33. However, at least one storage unit 5 remains at the unloading position 33.

[0070]

[0072] Subsequently, in a fifth step 65 the flipper device transports the lifted storage units 5 to the flipper position 37 which coincides in the exemplary embodiments with the loading position 31. The storage units 5 picked up from the top of the stack 3 that was originally placed in the unloading position 33 thus form the bottom of the flipped stack 3 at the loading position. In a sixth step 67 preferably all storage units 5 remaining at the unloading position 33 are transported to the loading position 31 by the flipper device 27 to complete the reordering of the storage units 5 in the stack 3.

[0073] The sequence of step 61 and steps 63, 65, 67 may be interchanged or may be carried out in parallel. For example, the shuttle 25 may move to the loading position 31 either while the lifting of the storage units 5 is underway or even after the stack 3 has been completely flipped.

[0074] Finally, in a seventh step 69 the flipped stack 3 is picked up by the shuttle 25 and transported out of the flipper channel 29. Advantageously, the distance to the first end 13 through which the shuttle 25 leaves the flipper channel 29 is comparatively short since the loading position 31 is closer to the first end 13 as the unloading position 33.

[0071] Reference numerals

[0072] 1 automated storage system

[0073] 3 stack of storage units

[0074] 5 storage unit

[0075] 7 storage position

[0076] 9 storage rack

[0077] 1 1 , 1 l a-1 l e storage channel

[0078] 13 first end

[0079] 15 second end

[0080] 17a, 17b first and second main aisle

[0081] 19 longitudinal direction

[0082] 21 lateral direction

[0083] 23 support rail

[0084] 25 shuttle

[0085] 27 flipper device

[0086] 29 flipper channel

[0087] 31 loading position

[0088] 33 unloading position

[0089] 35 gripping means

[0090] 37 flipper position

[0091] 39 control system

[0092] 41 bridge crane

[0093] 43 crane rails

[0094] 45 vertical direction

[0095] 47 upper guide rails

[0096] 49 indentation

[0097] 51 outer wall

[0098] 53 closed end

[0099] 55 door

[0100] 57-69 first to seventh step

Claims

Claims1 . An automated storage system ( 1 ) for stacks (3) of storage units (5), the automated storage system (1 ) comprising a storage rack (9) defining a plurality of storage channels (H al le), wherein each storage channel (l l a-l l e) of the plurality of storage channels extends parallel to a lateral direction and comprises two or more storage positions (7) for stacks (3) of storage units (5), wherein the two or more storage positions (7) are arranged consecutively in a direction extending parallel to the lateral direction (21 ), one or more shuttles (25) fortransporting stacks of storage units (3), wherein each shuttle (25) of the one or more shuttles (25) is configured to move parallel to the lateral direction (21 ) through each storage channel (l l a-l l e) of the plurality of storage channels (1 1 a- 1 1 e) and wherein each shuttle (25) is further configured for unloading a stack (3) of storage units (5) at an unloading position (33) of the two or more storage positions (7) of a flipper channel (29) of the plurality of storage channels (l l a-l l e) and retrieving a stack (3) of storage units (5) located at a loading position (31 ) of the two or more storage positions (7) of the flipper channel (29), and a flipper device (27) configured for forming a flipped stack (3) of storage units (5) at the loading position (31 ) by at least lifting one or more storage units (5) from a stack (3) of storage units (5) located at the unloading position (33) so that at least one storage unit (5) of the stack (3) of storage units (5) remains at the unloading position (33), placing the lifted one or more storage units (5) at a flipper position (37) of the two or more storage positions (7) in the flipper channel (29), lifting one or more remaining storage units (5) of the stack (3) of storage units (5) from the unloading position (33) and placing the lifted one or more remaining storage unit (5) on top ofthe storage units (5) which have previously been placed at the flipper position (37).

2. Automated storage system (1 ) according to claim 1 , wherein the wherein the unloading position (33) is located directly adjacent to the loading position (31 ).

3. Automated storage system (1 ) according to claim 1 or 2, wherein the flipper channel (29() extends between a first end (13) and a second end (15), wherein the loading position (31 ) is arranged between the first end (13) and the unloading position (33), and wherein the at least one shuttle (25) is configured for retrieving the flipped stack (3) of storage units (5) placed at the loading position (31 ) by the flipper device (27) and transporting the flipped stack (3) out of the flipper channel (29) via the first end (13) of the flipper channel (29).

4. Automated storage system ( 1 ) according to claim 3, wherein a first shuttle (25) of the one or more shuttles (25) is configured for entering the flipper channel (27) with a stack (3) of storage units (5) through the first end (13) or through the second end (15) and for unloading the storage units (5) at the unloading position (33).

5. Automated storage system (1 ) according to any of the preceding claims, wherein the flipper position (37) corresponds to the loading position (31 ) so that the flipped stack (3) of storage units (5) is formed at the flipper position (37).

6. Automated storage system (1 ) according to claim 1 , wherein the loading position (31 ) corresponds to the unloading position (33) and wherein the flipper device (27) is configured for moving storageunits (5) moved to the flipper position (37) bock to the combined loading (31 ) and unloading (33) position to form the flipped stack (3) of storage units (5) at the combined loading (31 ) and unloading (33) position.

7. Automated storage system (1 ) according to any of claims of the preceding claims, wherein each storage channel (1 l a-1 l e) comprises a pair of support rails (23) for supporting storage units (5), wherein the support rails (23) extend parallel to the lateral direction (21 ) on opposing sides of the storage channel (1 1 ), wherein each storage channel ( 1 1 a-1 1 e) is configured so that each of the at least one shuttle (25) can move below the support rail (23) parallel to the lateral direction (21 ) through the storage channel (1 19, and wherein the at least one shuttle (25) is configured for lifting a stack (3) of storage units (5) above the support rails (23) for transporting the stack (3) of storage units (5).

8. Automated storage system (1 ) according to any of the preceding claims, wherein the system further comprises a second shuttle (25) for transporting stacks (3) of storage units (5), wherein the second shuttle (25) is configured for retrieving a flipped stack (3) of storage units (5) located at the loading position (31 ), wherein the flipped stack (3) of storage units (5) comprises storage units (5) which have previously been placed at the at the unloading position (33) by a first shuttle (25).

9. Automated storage system (1 ) according to any of the preceding claims, wherein each storage unit (5) in a stack (3) of storage units (5) to be placed at the unloading position (31 ) comprises two opposing sidewalls, wherein each lateral sidewall comprises at leastone projection extending perpendicular to the lateral direction (21 ), and wherein the flipper device (27) comprises a gripping unit (35) which is configured for engaging with the at least one projection on each sidewall of a storage unit (5) for lifting the storage unit (5) and any storage unit (5) located on top of the storage unit (5) from a stack (3) of storage units (5).

10. Automated storage system (1 ) according to any of the preceding claims, wherein the storage system (1 ) comprises a first main aisle (17a), wherein the flipper channel (29) extends perpendicular to and away from the first main aisle ( 17a), wherein the storage system ( 1 ) preferably comprises a second main aisle (17b) extending parallel to the first main aisle (17a), wherein the flipper channel (29) extends between the first main aisle (17a) and the second main aisle (17b).1 1. A method for operating an automated storage system ( 1 ) according to any of the preceding claims, the method comprising the steps of transporting a stack (3) of storage units (5) comprising at least two storage units (5) with a first shuttle (25) by moving parallel to the lateral direction (21 ) through the flipper channel (29), unloading the stack (3) of storage units (5) from the first shuttle (25) at the unloading position (33), forming a flipped stack (3) of storage units (5) at the loading position (31 ) by at least lifting with the flipper device (27) one or more storage units (5) from the stack (3) of storage units (5) located at the unloading position (33) so that at least one storage unit (5) of the stack (3) of storage units (5) remains at the unloading position (33), placing with the flipper device (27) the lifted one or more storage units (5) at the flipper position (37), lifting with the flipper device(27) one or more of the at least one remaining storage unit (5) of the stack (3) of storage units (5) from the unloading position (33), and placing the lifted one or more remaining storage units (5) on top of the storage units (5) which have previously been placed at the flipper position (37), and retrieving with a shuttle (25) the flipped stack (3) of storage units (5) located at the loading position (31 ).

12. Method according to claim 1 1 , wherein the flipper channel (29) extends between a first end ( 13) and a second end (15) and the loading position (31 ) is arranged between the first end (13) and the unloading position (33), and wherein the first shuttle (25) retrieves the flipped stack (3) of storage units (5) from the loading position (31 ) and transports the flipped stack (3) out of the flipper channel (27) via the first end ( 13) of the flipper channel (27), wherein the first shuttle (25) preferably enters the flipper channel (27) with the stack (3) of storage units (5) through the first end (13) or wherein the shuttle (25) preferably enters the flipper channel (27) with the stack (3) of storage units (5) through the second end (15).

13. Method according to claim 1 1 , wherein the method further comprises the step of retrieving the flipped stack (3) of storage units (5) located at the loading position (31 ) with a second shuttle (25).

14. Method according to claim 1 1 , 12 or 13, wherein the flipper position (37) corresponds to the loading position (31 ) so that the flipped stack (3) of storage units (5) is formed by the flipper device (27) at the flipper position (37).

15. Method according to claim 1 1 , 12 or 13, wherein the loading position (31 ) corresponds to the unloading position (33) and wherein the flipper device (27) moves storage units (5) from the flipper position (37) back to the combined loading (31 ) and unloading (33) position to form the flipped stack (3) of storage units (5) at the combined loading (31 ) and unloading (33) position.

Images