Storage system for the compact three-dimensional storage of containers, and method for operating such a storage system

Abstract

The invention relates to a storage system (1) for the compact three-dimensional storage of containers (10), wherein a two-dimensional plane-based grid arrangement (2) of the storage system (1) is designed in such a way that the containers (10) can each be stored, with a container gap (L), in a container plane (11) side by side along a first horizontal coordinate axis (HK1) and side by side along a second horizontal coordinate axis (HK2). According to the invention, the containers (10) can be both loaded into and unloaded from their respective container planes (11) at the edge (4) of said container plane (11) by being pushed along each first coordinate axis (HK1) and each second horizontal coordinate axis (HK2) by means of the at least one handling device (100). The invention also relates to a method for operating such a storage system (1).

Description

[0001] Storage system for compact three-dimensional storage of containers and method for operating such a storage system

[0002] The invention relates to a storage system for the compact three-dimensional storage of containers according to claim 1 and to a method for operating such a storage system according to claim 10.

[0003] In the area of ​​logistics, i.e., the storage, retrieval, and safekeeping of items or goods in warehouses, warehouses should allow for the best possible use of space while maintaining high dynamics or high throughput and low costs. Conventional warehouses usually do not meet all of these requirements to the desired extent.

[0004] DE 102 23255 A1 discloses a storage system and method in which containers are moved along a coordinate axis in order to remove a container perpendicular to the direction of movement from a container row located behind these containers using a handling device. A container is removed using the same storage and retrieval device, with containers being moved along the coordinate axis to reach the container row located behind them, which is intended for the container to be removed.

[0005] WO 2016 / 172793 A1, US 2015 / 0127143 A1, WO 2020 / 011355 A1, WO 2019 / 238697 A1, and WO 2019 / 238661 A1 disclose robotic vehicles that move horizontally on top of the three-dimensional grid structure and perform a container exchange. However, the entire material flow takes place over the top of the warehouse.

[0006] EP 3 362 379 A1 discloses a storage system in which a type of carrier vehicle can move (drive) on the floor as well as climb up rails on the rack in order to move and store or retrieve storage units without the need for lifts or conveyors, etc.

[0007] It is also known to store loads in a level-based grid without aisles (“Puzzle-Based Storage” or “Grid-Flow Storage”). Here, storage units can be moved sequentially to gain access to the units behind them. This offers the possibility of operating even the most compact warehouses automatically (Gue, KR and BS Kim “Puzzle-Based Storage Systems”, Naval Research Logistics 54(5), pp. 556-567.) Due to the arrangement of the load units in a grid, high-density storage and sorting is achieved, since no aisles are required to reach the load units. If there is at least one empty space in the system, any desired load unit can be accessed. For this access, other load units may have to be moved.

[0008] WO 2007 / 007354 A1 describes a warehouse in which each of several levels is equipped with a network of transit guides along two orthogonal lines. The transit guides designate locations for individual objects. Robotic carts move alternately and sequentially on the guides of the two lines and are equipped with lifting and lowering devices to transport individual objects carried on sub-pallets. Objects to be stored are delivered to and retrieved from the warehouse at the edges.

[0009] DE 102018 105614 A1 describes a block warehouse with several storage locations arranged in an at least two-dimensional array of aisles in the X and Y directions, each for storing at least one load carrier. The block warehouse is equipped with a driverless transport system for storage and / or retrieval, which travels underneath at least one load carrier, lifts it, and moves it in the X and / or Y directions for handling. The driverless transport system is movable at least in the X and Y directions.

[0010] In contrast, the object of the present invention is to provide an alternative storage system for the compact three-dimensional storage of containers and a method for operating such a storage system, which has a high storage density and allows access to all containers in the system with minimal time and energy expenditure.

[0011] This object is achieved by the storage system having the features of claim 1 and the method having the features of claim 10. Advantageous embodiments emerge from the subclaims and the description.

[0012] According to the invention, a storage system for the compact three-dimensional storage of containers is provided, wherein a two-dimensional plane-based grid arrangement of the storage system is designed such that the containers can be stored in each container plane next to one another along a first horizontal coordinate axis and next to one another along a second horizontal coordinate axis with a container gap, wherein the first horizontal coordinate axis and the second horizontal coordinate axis are perpendicular to one another, and the container planes are arranged one above the other, and the containers in the respective container plane can be moved individually or in container groups by means of at least one handling device of the storage system from the edge of the container plane in the first horizontal coordinate axis and in the second horizontal coordinate axis in abutment directly on the floor of the container plane.The containers can be both loaded and unloaded via each first coordinate axis and each second horizontal coordinate axis solely by means of the at least one handling device in the respective container level at the edge of the respective container level by pushing.

[0013] In other words, the containers are stored level by level in the manner of puzzle-based storage or grid-flow storage directly on the respective floor area (without any intermediate means), but only need to be moved to the edge of the respective level to be picked up at any outer grid point. The containers and container groups, e.g. rows, are moved across the single container gap until the desired container reaches the edge of the level and can be picked up from there. This allows the shortest distance to the edge to be taken, as every point at the edge of the container level is suitable for picking, as the handling equipment can move there. Containers can be put into storage via any container gap at the edge, which can either be created by moving or already exist (e.g. directly after a retrieval process).The container groups are moved by contacting and pushing a container directly from the edge by the handling device. This container then passively pushes the other containers in the container group along the respective coordinate axis along which the group is to be moved.

[0014] In this case, "butt-to-end" means that the containers touch each other during movement, so that they are passively moved when a container is pushed at the beginning of a shifting sequence. The level-based grid arrangement comprises a plurality of upright supports and a container plane spanned perpendicularly to these supports along the first horizontal coordinate axis and the second horizontal coordinate axis. The containers can be stored and moved directly on the container planes. There are no intermediate means in the form of additional vehicles or movable support platforms. The load-bearing components of the storage system are the supports that support the container planes, on which the containers are stored. The supports are preferably arranged on the outside where possible so that the displacement movement of the containers is not impaired.

[0015] If it is necessary to arrange supports inside for static reasons, these internal supports can be designed with guide elements to prevent the containers from getting stuck when moving past a support.

[0016] For example, internal supports arranged within a container level could be provided with spring grids arranged on the outer sides or outer corners to guide the containers.

[0017] The level-based grid arrangement can be designed modularly, allowing for easy capacity expansion. This can be achieved by allowing supports of a first container level to also serve as supports of a second container level arranged at the same height.

[0018] To facilitate maintenance and segmentation of the working areas of the handling device(s) even within a container level, container-free empty rows can be provided, which can serve as access space for both maintenance personnel and the handling device(s). The container-free empty row can therefore extend along the first or second coordinate axis. This modularizes the container levels. This also allows the container groups that can be moved by the handling device to be kept manageable, since beyond a certain length or size of the container level, they can no longer be moved together without interference.

[0019] The spanned container planes or their surfaces can be used for

[0020] To reduce friction, they can be equipped with integrated rollers, balls, or sliding linings. This saves energy.

[0021] To prevent the containers from becoming jammed or stuck, the clamped container levels can be designed with mechanical guide rails or magnets for positioning and guiding the containers.

[0022] For example, guide rails can be arranged in a grid on the floor along the first or second coordinate axis, which can be divided into corresponding longitudinal or transverse sections.

[0023] The guide rails can be rigid or extendable. Furthermore, the guide rails can be arranged entirely or partially on the ceiling of the container levels, rather than just in the floor.

[0024] A contactless variant using magnets can also be used. Switchable electromagnets can be mounted on or in the base of the container level, and permanent magnets can be mounted in or on the underside of the container. The arrangement of the magnets is variable. For example, a magnet can be placed in the center, one at each corner, one on each side, etc. During the shifting process, the electromagnets are deactivated, and the containers can be moved freely.

[0025] Once a shifting operation is complete, one or more containers may not be completely centered along the corresponding coordinate axis. In this case, a short pulse from selected electromagnets may be sufficient to pull the containers toward them and thus center them.

[0026] A push force sensor on the handling unit can serve as a safety sensor, so that if a specified force threshold is exceeded, it can be assumed that the container is blocked. Maintenance personnel or maintenance units (e.g., separate handling units) can then be notified. The use of other sensors (e.g., cameras) on the handling unit and / or on the grid arrangement is also conceivable.

[0027] Appropriately positioned elastic wear parts, such as rubber stoppers, etc., would also be conceivable.

[0028] Such measures also prevent unwanted displacement of the containers due to vibrations, etc., as they fix the position of the containers when stationary.

[0029] The containers are moved from the edge solely by at least one handling device, in which a container close to the edge is actively pushed and this in turn passively pushes the other containers in a shifting row by impact.

[0030] For this purpose, the handling device can be designed as a guided device on the edge of the upright outer supports and / or on the spanned container levels of the level-based grid arrangement and / or as a robot vehicle that can move freely on the floor.

[0031] It is possible to design the handling device as a purely climbing unit on the supports, which cooperates with other AGVs / AMRs on the ground to transfer or hand over containers. It would also be possible to design it as a unit that can also move along the ground. For transverse movement at the container level, crossbeams of the supporting structure or separate guide rails can be used. Both the supports and the transverse movement mechanism can be equipped with power charging mechanisms to supply the handling device and / or enable charging of power storage devices (power caps, batteries, etc.). The power charging mechanism can operate inductively or, for example, via a collector (conductor line).

[0032] In other words, the handling device must be able to move along the outside of the grid arrangement and push containers within it or on a container level both to the left and right and forward, i.e. in both coordinate axis directions.

[0033] The handling device can therefore be configured to move containers in a first coordinate axis and a second horizontal coordinate axis of the respective container plane.

[0034] The handling device could also be equipped with a multi-stage shifting mechanism, e.g., in the form of multiple telescopic stages, to shift containers further, e.g., by two or even three grid positions (storage locations). Furthermore, the handling device can be designed to pick up and transport individual containers, e.g., by pulling them onto itself, for example, during the retrieval of a target container.

[0035] The handling device is therefore designed to hold a container.

[0036] The simultaneous use of multiple handling devices is also conceivable. Simultaneous use can take place on the same or different levels. Multiple handling devices can cooperate or be controlled cooperatively. For example, two handling devices can operate on different sides of a container group. One handling device pushes, while the other simultaneously picks up the moved target container. This results in faster moving or provisioning of the target containers.

[0037] The handling device can be powered by a battery or by charging contacts / inductive charging using the shelf rails.

[0038] The term "compact" in the context of the invention means that no handling device is arranged between the containers, as is the case, for example, in storage systems with parallel storage racks and storage and retrieval machines arranged in a rack aisle between them. Thus, no free space required for direct removal of goods is reserved, but is created only when needed. Furthermore, only the smallest possible free space is created for removing the container and / or article, which preferably corresponds to a single container width or length.

[0039] The three-dimensional grid arrangement is preferably cuboid-shaped and has at least one container-free storage space in each container level into which the containers can be moved or shifted.

[0040] The at least one first horizontal coordinate axis along which the containers are movable or displaceable is the X-axis. The at least one second horizontal coordinate axis is the Y-axis, which is arranged perpendicular to the X-axis.

[0041] The storage system according to the invention has a high storage density and allows direct access to the goods with minimal time and energy expenditure.The invention further relates to a method for operating a storage system according to one of the preceding claims, wherein containers stored next to one another in the two-dimensional plane-based grid arrangement of the storage system are displaced individually or in container groups along the first horizontal coordinate axis and along a second horizontal coordinate axis by exactly one container width or container length, solely by means of the first handling device of the storage system from the edge over the at least one container gap, until a desired container is positioned at the edge region of the container plane and then the desired container is retrieved from the edge of the container plane either in the first horizontal coordinate axis or in the second horizontal coordinate axis by means of the first handling device.

[0042] In other words, the containers and container groups, e.g., rows, are moved across the one container gap until the desired target container reaches the edge of the level and can be removed there. This allows the shortest distance to the edge to be taken, since any point at the edge of the container level is suitable for removal, as the handling device can move there.

[0043] The storage system according to the invention has a controller which is designed and configured to carry out the method according to the invention.

[0044] Further details of the invention emerge from the following description of embodiments with reference to the drawing, in which

[0045] Fig. 1 is a schematic perspective view of a storage system for compact three-dimensional storage of containers,

[0046] Fig. 2 is a schematic plan view of a section of a three-dimensional lattice structure of the storage system from Figure 1,

[0047] Fig. 3 is a schematic plan view of an exemplary three-dimensional lattice structure when moving a target container,

[0048] Fig. 4 is a schematic plan view of a section of a three-dimensional grid structure of the storage system of Figure 1 during removal of a container; and

[0049] Fig. 5 is a schematic perspective view of a handling device on the storage system of Figure 1;

[0050] Fig. 6 is a schematic plan view of a variant of a storage system;

[0051] Fig. 7 is a schematic side view of a container with a guide interacting with the bottom of the container;

[0052] Fig. 8 is a schematic plan view of a section of a container level with internal supports and

[0053] Fig. 9 shows a schematic plan view of a container plane with centering mechanism.

[0054] The figures show a storage system, designated as a whole by 1, for the compact three-dimensional storage of containers 10.

[0055] It is designed by a two-dimensional plane-based grid arrangement 2 such that the containers 10 can be stored in a container plane 11 next to each other along a first horizontal coordinate axis HK1 and next to each other along a second horizontal coordinate axis HK2 with at least one container gap L.

[0056] The first horizontal coordinate axis HK1 (X-direction) and the second horizontal coordinate axis HK2 (Y-direction) are perpendicular to each other and the container levels 11 are arranged vertically one above the other in the Z-direction.

[0057] In other words, the containers 10 are arranged in mutually perpendicular rows 3a, 3b in the respective container plane 11, and these container planes 11 are arranged vertically one above the other. The plane-based grid arrangement 2 comprises a plurality of upright and outwardly arranged supports 6. The container planes 11, spanned perpendicularly thereto along the first horizontal coordinate axis HK1 and the second horizontal coordinate axis HK2, have guide rails 7 at their edges.

[0058] The clamped container levels 11 are provided with sliding linings to reduce friction.

[0059] This results in a cube-shaped structure, with the respective container levels 11 initially independent of each other. The structure is compact because there are no conventional rows or aisles for access.

[0060] Access to containers or their relocation takes place only via the edge 4 of the respective container level 11 by handling devices 100 designed as robot vehicles that can be moved there.

[0061] These robot vehicles 100 can climb up along the outside of the supports 6 and move across the container levels 11 along the guide rails 7.

[0062] The robot vehicles 100 each have a container sliding mechanism 101, with which the containers 10 in the respective container level 11 can be moved in a push-pull manner, individually or in container groups 12, e.g. rows, from the edge 4 of the container level 11 in the first horizontal coordinate axis HK1 and in the second horizontal coordinate axis HK2 (see Figures 2 and 3 below).

[0063] For this purpose, the container sliding mechanism 101 comprises a linearly extendable stamp 102 and an adjoining gripping head 103, which is designed to partially grip the adjacent container 10 with side walls 103 a, b.

[0064] By means of the container shifting mechanism 101, a single container 10 or a container group 12 can be shifted by at least one container length or container width. If the containers 10 are square in cross-section, as in this case, a checkerboard-like arrangement results, and thus also a linear shift in the direction of the second coordinate axis HK2 or in the Y direction by extending the piston 102 (see Figure 2A). For transverse displacement in the direction of the first coordinate axis HK1 or in the X direction, the robot vehicle 100 grasps the respective container 10 located at the edge with the side walls 103a, b and moves itself along the guide rail 7 in the desired direction and by the required amount (see Figure 2B).

[0065] In order to move a desired target container 10* from a position within the container plane 11 to the edge 4 into the direct access area of ​​a robot vehicle 100, the containers 10 and container rows 12 can be moved alternately in the directions of the first coordinate axis HK1 or X direction and the second coordinate axis HK2 or Y direction until the desired target container 10* reaches the edge 4.

[0066] This is illustrated by way of example in Figure 3 using shifting movements i) - vii). There, first, in movement i, two containers 10 are pushed inwards into gap L as row 12.1. Then, in movement ii, a single container is pushed into the newly created gap L2. After that, the entire row 12.2 of containers is pushed into the new gap L3 in movement iii. The now created gap L4 can thus be used to accommodate container row 12.3 from movement iv. Then, in movement v, the outer row of containers 12.4 is pushed into gap L5, creating a gap L6 at the corner. Container row 12.5 can be pushed into this gap in movement vi, creating a gap L7 at the edge in front of the target container 10*, into which the target container 10* is pushed by a final movement vii of row 12.6 and is now accessible (see Figure 4 bottom).

[0067] Furthermore, the robot vehicles 100 have a receptacle 104 (see Figure 4) into which containers 10 can be received for transport. For this purpose, the container pushing mechanism 101 can be configured as an additional pulling mechanism. Alternatively, another robot vehicle 100 can push the corresponding container row 12 from the opposite side so that the desired container 10 is pushed onto the waiting robot vehicle 100 into the receptacle 102.

[0068] The robot vehicle 100 can then leave the respective container level 11 and climb down to the hall floor 5 (or possibly an intermediate level), where it can hand over the container 10 to a waiting AGV or AMR 9 that has been ordered there by a higher-level central controller 200.

[0069] As shown in Figure 5, the robot vehicle 100 can positively engage with racks 16 of the supports 6 using a drive 105 to move up and down along them. Similarly, a drive 106 can interact with the guide rails 7 for transverse movement in the plane.

[0070] Figure 6 shows a variant of the storage system 1 in which the level-based grid arrangement 2 is modularly designed and a container-free empty row 13 is arranged between two modules 2A, 2B or their upright supports 6 in the direction of the first or second coordinate axis HK1, HK2. This empty row 13 allows, on the one hand, access for a robot vehicle 100, so that the size of the container rows 12 to be handled remains manageable, and, on the other hand, access for any necessary maintenance.

[0071] The storage system 1 according to the invention can be equipped with mechanical guide rails or magnets in the clamped container levels 11 for positioning and guiding the containers 10.

[0072] Figure 7 shows a variant with mechanical guide rails 14.

[0073] Thus, along the first and second coordinate axes HK1, HK2, guide rails 14 a, b can be arranged in a grid on the bottom of the container level 11, which engage in corresponding longitudinal or transverse recesses 10 a, b in the container bottom 10c.

[0074] The guide rails 14 are designed to be retractable and extendable into recesses 11a, b in the floor. This guides the containers 10 during pushing and prevents them from slipping or being displaced by vibrations, even when stationary.

[0075] Figure 8 shows a variant in which, for example, for static reasons, the container levels 11 have inner supports 6A in addition to the outer supports 6 in order to handle the load. To ensure that the containers 10 do not get caught on these inner supports during the sliding process and possibly become wedged, the inner supports 6A are provided on all four sides with spring catches 15 to guide the containers 10. These prevent the containers 10 from getting caught on the inner supports 6A. The spring-loaded catches 15 can initially give way due to the pressure against the spring upon contact with the containers 10 during sliding (see arrow) and then spring back to ensure that the containers 10 are positioned. It is understood that the distances shown are enlarged for illustrative purposes.

[0076] As shown in Figure 9, a contactless variant using magnets 17 or 18 can also be used. Switchable electromagnets 18 are mounted on or in the base of the container level 11, and permanent magnets 17 are mounted centrally in or on the underside of the containers 10. During the shifting process, the electromagnets 18 are deactivated, and the containers 10 can be moved freely.

[0077] Once a shifting operation is completed, it may be the case that a container 10 is not quite centered along the corresponding coordinate axis HK1, HK2. In this case, a short pulse from one (or optionally all or specific areas) of the electromagnet 18 to be activated may be sufficient to attract the container 18 toward itself and thus center it. The controller 200 is configured accordingly. It is also possible to execute a pulse at the beginning of a shifting operation to ensure that the containers are aligned before shifting.

[0078] A pushing force sensor 19 on the handling unit 100 serves as a safety sensor, so that if a predetermined force threshold is exceeded, it can be assumed that a container blockage has occurred. Maintenance personnel or maintenance units (e.g., separate handling units) can then be notified if alignment using the magnets 17, 18 is unsuccessful.

Claims

Patent claims 1. Storage system (1) for the compact three-dimensional storage of containers (10), wherein a two-dimensional plane-based grid arrangement (2) of the storage system (1) is designed such that the containers (10) can be stored in a container plane (11) next to one another along a first horizontal coordinate axis (HK1) and next to one another along a second horizontal coordinate axis (HK2) with a container gap (L), wherein the first horizontal coordinate axis (HK1) and the second horizontal coordinate axis (HK2) are perpendicular to one another, and the container planes (11) are arranged one above the other,and the containers (10) in the respective container level (11) can be moved individually or in container groups (12) solely by means of at least one handling device (100) of the storage system (1) from the edge of the container level (11) in the first horizontal coordinate axis (HK1) and in the second horizontal coordinate axis (HK2) directly on the floor of the container level (11), characterized in that the containers (10) can be both stored and retrieved by pushing along each first coordinate axis (HK1) and each second horizontal coordinate axis (HK2) solely by means of the at least one handling device (100) in the respective container level (11) at the edge of the respective container level (11).

2. Storage system (1) according to claim 1, characterized in that the level-based grid arrangement (2) has a plurality of upright supports (6) and container levels (11) spanned perpendicularly thereto along the first horizontal coordinate axis (HK1) and second horizontal coordinate axis (HK2), wherein the containers (10) can be stored and moved on the container levels (11).

3. Storage system (1) according to claim 2, characterized in that inner supports (6) arranged within a container level (11) are provided with spring catches (15) arranged on the outer sides (6*A) or outer corners for guiding the containers (10).

4. Storage system (1) according to one of claims 2 or 3, characterized in that the level-based grid arrangement (2) is designed modularly and a container-free empty row is arranged between two modules or their upright supports (6) in the direction of the first or the second coordinate axis (HK1, HK2).

5. Storage system (1) according to one of claims 2 to 4, characterized in that the clamped container levels (11) are provided with rollers, balls or sliding linings to reduce friction.

6. Storage system (1) according to one of claims 2 to 5, characterized in that the clamped container levels (11) have mechanical guide rails (14A, B) or magnets (11C) for positioning and guiding the containers (10).

7. Storage system (1) according to one of claims 1 to 6, characterized in that the handling device (100) is designed as guided on the edge of the upright outer supports (6A) and on the spanned container levels (11) of the level-based grid arrangement (2) and / or as a robot vehicle that can be moved freely on the floor.

8. Storage system (1) according to claim 7, characterized in that the handling device (100) is designed to move containers (10) in a first horizontal coordinate axis (HK1) and a second horizontal coordinate axis (HK2) of the respective container plane (11).

9. Storage system (1) according to claim 7 or 8, characterized in that the handling device (100) is arranged to receive a container (10).

10. A method for operating a storage system (1) according to one of the preceding claims, wherein in the two-dimensional plane-based grid arrangement (2) of the storage system (1), containers (10) stored next to one another directly on the floor of the container plane (11) are displaced individually or in container groups (12) along the first horizontal coordinate axis (HK1) and along a second horizontal coordinate axis (HK2) exactly by one container width or container length, solely by means of the first handling device (100) of the storage system (1) over the one single container gap (L), until a desired container (10) is positioned at the edge region of the container plane (11) and then the desired container (10) is retrieved from the edge of the container plane (11) either in the first horizontal coordinate axis (HK1) or in the second horizontal coordinate axis (HK2) by means of the first handling device (100).

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