Grid storage system with above grip atu

Abstract

A port storage and distribution system for facilitating the transfer and / or storage of international shipping containers between container ships and ground transport carriers wherein an overhead grid guide track structure is provided that permits overhead transfer units to selectively engage and convey containers as required between the various ships, carriers and storage area without requiring multiple transfers of containers between different handling equipment. The overhead transfer units sit on top of, engage, and move upon an X-Y grid track of the overhead grid guide track structure.

Description

[0001] STORAGE AND DISTRIBUTION SYSTEM FOR SHIPPING AND STORING CONTAINERS, FRAMES OR OTHER DEVICES TO STORE AND TRANSPORT MILITARY, CONSUMER AND COMMERCIAL GOODS, VEHICLES, BOATS, WAREHOUSE ITEMS AND SELF STORAGE ITEMS AND THE LIKE.

[0002] BACKGROUND OF INVENTION

[0003] Field of Invention

[0004] This application is directed to a storage and distribution system wherein closed and open containers, frames, or other similar devices are manipulated by one or more overhead automated transfer units (ATUs) that can lift or elevate the items and maneuver them to vertical columns or stacks that are end to end and side by side, using an elevated GRID system without the need to use conventional cranes, and the like, and in such a manner as to maximize storage space by eliminating the need for aisles, minimize spaces between rows and the ends of containers for manipulating and / or handling equipment. The transfer units are driven along overhead guide tracks by one or more drive wheels or by one or more linear induction motors working in combination with one or more air bearings supporting the transfer units.

[0005] Brief Description of the Related Art

[0006] As known in the art, the containers are typically closed boxes, open frames and the like such as used for overseas containers used for shipping goods via ships from one country to another, called ISO containers ranging from 20 feet long by nomically 8 feet wide and 8 feet high including 40 feet and 45 feet long containers military items as well as other sized containers, frames, flat racks and the like to store vehicles, boats, warehouse items and self- storage items of different sizes as well warehouse items and pallets.

[0007] The transfer unit is equipped with hoists that attach to the four comers of a spreader beam which adjust to fit the four corners of containers ranging from virtually any length, width or height but typically 20 feet long and 8 feet wide and 8 feet high and various heights, 40 feet long by 8 feet wide and 45 feet long by 8 feet wide in a vertical # arrangement with the lift cables (wire ropes) connected near or on the spreader beam four corners. The spreader is adjustable to fit the size of each container or frame.

[0008] US 7,753,637 B2 and US 8,206,074 B2 to Benedict et al. teaches a port storage and distribution system utilizing an overhead grid oriented in an X-Y pattern. The overhead grid includes hollow box beams oriented in the X-Y pattern. The transfer units hang from and travel along the hollow box beams via multiple carriage plates positioned within the box beams and secured to the transfer units.

[0009] US 10,023,384 B2 to Benedict teaches an automated storage system utilizing an overhead grid oriented in an X-Y pattern. The overhead grid includes I-beams oriented in the X-Y pattern. The transfer units hang from and travel along lower flanges of the I- beams via multiple carriage plates positioned around the lower flanges of the I-beams and secured to the transfer units.

[0010] US 10,829,303 B2 to Benedict teaches an automated storage system utilizing an overhead grid oriented in an X-Y pattern. The overhead grid includes T-beams oriented in the X-Y pattern. The transfer units hang from and travel along flanges of the T-beams via multiple carriage plates positioned around the flanges of the T-beams and secured to the transfer units.

[0011] The various patents referenced above have been granted addressing the features of overhead storage systems using box Beams, I-Beams and T-beams as rails used as the transport medium for an overhead track system to support a carriage within or on each rail configurations. In each reference, the transfer unit attaches to, hangs from, and moves along the rails via one or more carriage plates having a series of spherical ball bearings and unidirectional rollers attached to the underside of each carriage plate within the rail system. The carriage plates are attached to a transfer unit (TU) by a solid shaft through a slot in the lower surface of a box beam or around the edges of the flange of an I or T beam rail system arranged in an X-Y, or 90-degree configuration. The spherical ball bearings assist the carriage plates cross openings present at rail intersections along the X-Y rail system slots for the carriages attached to the top of the transfer unit.

[0012] However, the use of spherical ball bearings and unidirectional rollers, or similar mechanical means of movement, has drawbacks. The transfer units are constantly # picking up and moving extremely heavy loads which quickly wear down any rollers or ball bearings used to move the transfer unit along the guide system. Maintenance downtime and associated costs can add up quickly. With so many rollers in each carriage plate, the rails must be constantly kept clear as any debris on the rails could impair movement of the transfer units. Further, a simple X-Y configuration of the rail system causes logistic issues, as two transfer units cannot use the same rail when traveling in opposite directions and thus must be at least one cell apart at all times. As described herein, a “simple X-Y configuration” describes a first plurality of parallel rails or tracks oriented in a first direction and a second plurality of rails and tracks transversely and perpendicularly oriented in a second direction relative to the first plurality of parallel rails or tracks, such that each rail or track of the first plurality of parallel rails or tracks is equally spaced from adjacent rails or tracks of the first plurality of parallel rails or tracks and each rail or track of the second plurality of parallel rails or tracks is equally spaced from adjacent rails or tracks of the second plurality of parallel rails or tracks.

[0013] Under certain conditions it would be advantageous to have one or the other orientations or a combination of the two layouts, depending on the configuration of the system requirements.

[0014] It would be advantageous to reduce the time and cost of maintaining such automated container systems. Further, it would be advantageous to improve the efficiency of transfer unit movement along the X-Y grid system.

[0015] SUMMARY OF THE INVENTION

[0016] The invention of the present application includes shipping container storage and distribution system being made of an overhead grid guide track structure including a plurality of tracks extending transversely with respect to one another in an intersecting X-Y pattern; at least one transfer unit moveably mounted to and positioned above the grid guide track structure and secured within at least two spaced and parallel first tracks # of the plurality of tracks when moving in a first direction and at least two spaced and parallel second tracks of the plurality of box beams or other structural shapes such as I- Beams, T-Beams or the like when moving in a second direction transverse to the first direction; each transfer unit of said at least one transfer unit having a plurality of air bearings secured within the grid guide track structure to lift the automated transfer unit (ATU) relative to the plurality of tracks; and each said transfer unit of said at least one transfer having a lateral movement means configured to move each said ATU along said plurality of tracks in said first direction and said second direction, the tracks being the upper surfaces of Box beam, I-beams, T-beams or the like being supported by a structural system.

[0017] Another aspect of the invention includes an ATU including a housing having a central frame and a plurality of support members extending all in a same direction from the central frame to the guide track system; one or more air compressors secured to the central frame; one or more hoist motors secured to the central frame; one or more winding drums connected to and rotatable by the one or more hoist motors mounted on an adjustable trolley mountable within the central frame of the transfer unit; a cable attached to each winding drum of the one or more winding drums, the cable extendable and retractable relative to the central frame; and an adjustable spreader beam secured to the cable of said each winding drum; wherein an air bearing carriage is secured to an end of each support member of said plurality of support members of the housing, the air bearing carriage having a bearing housing with a plurality of openings along a bottom surface of the bearing housing, the one or more air compressors configured to supply pressurized air to the bearing housing via a corresponding air shaft oriented in a corresponding member of the plurality of support members such that the pressurized air is forced out of the plurality of openings along the bottom surface of the bearing housing.

[0018] A further aspect of the invention includes a method of transporting a shipping container between a ship and a secondary location destination, the method including unloading the shipping container from a ship onto a bomb cart type vehicle located on a # transfer platform positioned between the ship-to-shore crane and the overhead grid system; placing the container on the bomb cart type vehicle under an overhead grid system; the transfer platform attached to the ship-to-shore crane and movable with the ship-to-shore crane or independently movable in sync with the ship-to-shore crane, the bomb cart type vehicle movable on the transfer platform from the ship-to-shore crane to under the overhead grid system, picking up the shipping container with an ATU of an overhead grid system; moving the shipping container to the secondary location along the overhead grid system via the ATU; and depositing the shipping container at the secondary location via the ATU. The overhead grid system used in the method includes an overhead grid guide track structure having a plurality of tracks extending transversely with respect to one another in an intersecting X-Y pattern; the transfer unit moveably mounted to and positioned above the grid guide track structure and secured within at least two spaced and parallel first tracks of the plurality of tracks when moving in a first direction and at least two spaced and parallel second tracks of the plurality of Box beams, I-Beams or T-Beams when moving in a second direction transverse to the first direction; each transfer unit of said at least one transfer unit having a plurality of air bearings secured within the grid guide track structure to lift the transfer unit relative to the plurality of tracks; and each said transfer unit of said at least one transfer unit having a lateral movement means configured to move each said transfer unit along said plurality of tracks in said first direction and said second direction.

[0019] Another aspect of the invention includes a shipping container storage and distribution system, comprising a port crane configured to unload shipping containers from a cargo ship; a transfer platform for transitioning the shipping containers from the port crane to an overhead grid guide track structure; the overhead grid guide track structure including a plurality of tracks extending transversely with respect to one another in an intersecting X-Y pattern; at least one transfer unit moveably mounted to and positioned above the grid guide track structure and secured within at least two spaced and parallel first tracks of the plurality of tracks when moving in a first direction and at least two spaced and parallel second tracks of the plurality of Box beams, I- # beams, T-beams or the like when moving in a second direction transverse to the first direction; each transfer unit of said at least one transfer unit having a plurality of air bearings secured within the grid guide track structure to lift the transfer unit relative to the plurality of tracks; and each said transfer unit of said at least one transfer having a lateral movement means configured to move each said transfer unit along said plurality of tracks in said first direction and said second direction.

[0020] Another aspect of the invention includes a container, ben, frame or the like in a system such as a self-storage facility, warehouse, dry stack marina, vehicle parking garage of the like wherein the article being stored is either driven in to, placed by means of a crane, lift or other means such as a transfer platform, the storage system being made of an overhead grid guide track structure including a plurality of tracks extending transversely with respect to one another in an intersecting X-Y pattern; at least one transfer unit moveably mounted to and positioned above the grid guide track structure and secured within at least two spaced and parallel first tracks of the plurality of tracks when moving in a first direction and at least two spaced and parallel second tracks of the plurality of box beams when moving in a second direction transverse to the first direction; each transfer unit of said at least one transfer unit having a plurality of air bearings secured within the grid guide track structure to lift the automated transfer unit (ATU) relative to the plurality of tracks; and each said These aspects of the invention, and additional embodiments of each, are described in further detail herein.

[0021] BRIEF DESCRIPTION OF THE DRAWINGS

[0022] A better understanding of the invention will be had with reference to the attached drawings wherein:

[0023] Fig. 1 is a perspective view of an embodiment of a shipping container storage and distribution system in accordance with the teachings of the present invention, illustrating the transfer of a shipping container from a container ship to an elevated transfer platform on which the container is placed so as to be subsequently engaged by # an overhead transfer vehicle or unit to be moved within an overhead grid guide track or rail system to either be stored, placed on a ground carrier for transport, or transferred to another container ship;

[0024] Fig. 2 is a perspective of a representative container placed on the transfer platform from a port crane;

[0025] Fig. 3 is a perspective view of the container on the transfer platform and engaged by a transfer unit of the overhead grid guide track system;

[0026] Fig. 4 is a end view of the container fully engaged within the transfer unit for lateral movement along the overhead grid guide track system;

[0027] Fig. 5 is a end view of the transfer unit holding the container as it moves over a storage cell for depositing containers in a storage area;

[0028] Fig. 6 is a end perspective view of the transfer unit depositing the container in the storage area via the storage cell;

[0029] Fig. 7 is a end view of the transfer unit with the fully engaged container moving along an intersection of the overhead grid guide track system;

[0030] Fig. 8 is a perspective view of the transfer unit depositing the container on a truck along an end of the overhead grid guide track system;

[0031] Fig. 9 is a perspective view of the transfer unit depositing the container on a train along the end of the overhead grid guide track system;

[0032] Fig. 10A is a perspective side view of along a side of a transfer unit embodiment of the present invention;

[0033] Fig. 10B is an end view of the transfer unit of Fig. 10A;

[0034] Fig. 10C is a top view of the transfer unit of Fig. 10A;

[0035] Fig. 10D is an end view a shuttle housing a hoist and motor system of the transfer unit of Fig. 10A;

[0036] Fig. 10E is a further end view of the shuttle of Fig. 10D secured along a rack and pinion system;

[0037] Fig. 11 A is a top perspective view of an air bearing carriage embodiment of the transfer unit of Fig. 10A;

[0038] # Fig. 11 B is a bottom perspective view of an air bearing carriage embodiment of the transfer unit of Fig. 10A;

[0039] Fig. 12A is a bottom view of an embodiment of the air bearing carriage moveable with a linear induction motor system;

[0040] Fig. 12B is a bottom of an embodiment of the air bearing carriage moveable with a different configuration of a linear induction motor system;

[0041] Fig. 13 is a perspective view of a transfer unit secured to the overhead grid guide track system;

[0042] Fig. 14A is a perspective view along an end of the transfer unit;

[0043] Fig. 14B is a magnified perspective view of Fig. 14A showing the air bearing carriage positioned with tracks of the overhead grid guide track system;

[0044] Fig. 15A is a perspective view along a port side of an alternative embodiment of the shipping container storage and distribution system having solar panels secured to a roof over the overhead grid guide track system;

[0045] Fig. 15B is a perspective view along a transport side of an alternative embodiment of the shipping container storage and distribution system having solar panels secured to a roof over the overhead grid guide track system;

[0046] Fig. 16 is a perspective view of a spreader beam embodiment of the transfer unit of Fig. 10A; and

[0047] Fig. 17 is a perspective view of a section of overhead grid guide track system used in testing the system and transfer unit;

[0048] Fig. 18 is a perspective view of an alternate embodiment of the transfer platform and bomb cart type vehicle of Fig. 2; and

[0049] Fig. 19 is a perspective view of the transfer platform embodiment of Fig. 18 without the bomb cart type vehicle.

[0050] DESCRIPTION OF PREFERRED EMBODIMENTS

[0051] # With continued reference to the drawings, the container storage and distribution systems having an overhead grid guide track or rail system will be described wherein air bearings are used to lift ATUs, or transfer units, of the overhead grid guide track or rail system relative to tracks or railing, where motorized movement means are used to laterally propel the transfer units along the tracks or railing. Several embodiments of the invention will be described.

[0052] A first embodiment of a representative port facility utilizing an embodiment of the container storage and distribution system 1 is shown across Figs. 1 -9.

[0053] Fig. 1 shows the storage and distribution system 1 having a docking berth area 10 and multiple transportation lanes 30. The system 1 may include multiple docking berth areas 10, each for docking a container ship (S). Further, docking berth areas 10 may be located around any side of the system 1 , including one or more docking berth areas around multiple sides of the system.

[0054] Transportation lanes 30 may include one or more lanes for automotive vehicles, especially trucks (T). Transportation lanes 30 may additionally or alternatively include one or more lanes having railroad tracks for trains (TN) to operate upon. The precise location of the transportation lanes may vary and need only be located partially under an overhead grid guide track system 60, as described further herein, to receive one or more containers (C) from transfer units (TU) 100.

[0055] A container ship (S) is a specialized vessel which is specifically designed to maximize the storage capacity of international storage and shipping containers (C). Conventional container ships (S) include one or more hold areas, not shown, extending from a bow to a stern of the ship with each hold area being divided into a plurality of vertically tiered cells. The cells are open vertically and are defined by generally V- shaped steel guideposts which are positioned at the four corners of each cell. The steel guideposts are spaced in such a manner that conventionally dimensioned international shipping containers (C) may be positively guided when being lowered into or being raised within the cells. In this manner the containers may be stacked one upon another within each cell. Typical cells may retain as many as six or more stacked containers.

[0056] # Each hold is typically reinforced by a plurality of fore and aft extending steel beams and starboard to port extending beams, each of which is constructed to coincide with the cells. This grid structure is sealed utilizing conventional hatch covers, not shown, which are removably mounted in a conventional manner to the structure. There are typically seven storage tiers in each cell of the hold area and are seven cells in width between the starboard and port side of the ship’s hull.

[0057] Preferably, the first six tier levels are completely filled with storage containers (C), however, approximately half of the seventh tier of each of the cells is left vacant or empty upon the initial loading of the vessel to allow for storage containers (C) to be shuffled within the cells of the vessel. A container located on the sixth tier may be elevated and placed in the seventh tier of one of the cells and, in like manner, the underlying container in the fifth tier may also be raised and placed in an empty seventh tier of another cell. In this manner, access can be obtained to any of the containers within a cell without requiring that the containers be elevated out of the hold area of the ship.

[0058] Once a desired container is exposed, the container may be elevated and discharged from the ship by use of a gantry crane 20 that is disposed along a dock side of the system 1 to be movable relative to the ship’s hold. As opposed to using a shorebased gantry crane, in some instances it may be possible to use one or more conventional ships cranes utilizing conventional hoist line equipment, not shown, to elevate containers from the storage cells and move them toward the on-shore handling equipment of the present invention. In such an embodiment, the onboard ship crane would deposit the containers on an independently movable transfer platform 40.

[0059] As shown in Fig. 2, a gantry crane 20 modified according to the present invention includes an elevated transfer platform 40 horizontally extending away from the back of the gantry crane’s rearward vertical supports 24. The gantry crane 20 typically includes four vertical supports 24 being support legs that are mounted to rollers or wheels 26, shown in Fig. 6, such that the gantry crane may be moved along guide tracks 28, also shown in Fig. 6, to adjust the positioning of the gantry crane relative to the ship S. The # gantry crane 20 also includes a horizontally oriented boom 21 secured to the vertical supports 24 and positioned above the transfer platform 40. An attachment mechanism, not shown, is secured to the boom for attaching to the containers C. This attachment mechanism, typically a spreader beam, is secured to the boom 21 via cables and is vertically movable up and down relative to the boom. The attachment mechanism is also horizontally moveable relative to the boom between a ship end 22 and a port end 23 of the boom. In operation, the attachment mechanism descends downwardly from the boom 21 at the ship end 22, attaches to container C located on the container ship S, is retracted upwardly toward the boom, moves horizontally toward the port end 23 until over the transfer platform 40, descends downwardly to place the container on a bomb cart type vehicle on the transfer platform, is retracted upwards toward the boom, and then moves horizontally back toward the ship end 22 to begin the process over.

[0060] The transfer platform 40 preferably has safety railing around a perimeter of the platform, as well as access means 46, being stairs, a ladder, elevator, etc., for human operators (H) to access the platform and safely work atop the platform. The operators work on the platform 40 to release the twist locks on the bottom of the container (C) from the receptacle mechanism. The bomb cart type vehicle 42 then moves the container to a position underneath an end cell opening 74A (Fig. 3) of the overhead guide track system 60 for pickup by a transfer unit 100. Preferably, the movement of the container across the transfer platform 40 to the position under the end cell opening 74A of Fig. 3 is automated, as will be explained further herein. The bomb cart type vehicle 42 may include a plurality of air bearings, wheels, or rollers on the bottom surface for moving it and the container across the transfer platform 40. Preferably, the bomb cart type vehicle 42 has one or more air-bearing carriages 108 (Fig. 10B), as described further herein, for lifting the bomb cart type vehicle and container upwards via pressurized air, in addition to the stated means for lateral movement. The bomb cart type vehicle 42 is appropriately shaped to safely hold and move a container C on the transfer platform 40.

[0061] # In an embodiment shown in Figs. 18 and 19, the bomb cart type vehicle 42 may be powered through electrical rails 50 located directly under the surface of the transfer platform 40, and electrically accessible to an electrical contact extending from a bottom of the bomb cart type vehicle. The electrical rails are there to power the air compressors and / or motorized wheels on the bomb cart type vehicle via the electrical contact, not shown. The preferable means to drive the bomb cart type vehicle is using electrically or pneumatically driven wheels, not shown, located at each corner of the bomb cart type vehicle. Air compressors, not shown, supply pressurized air to air bearings on the bomb cart type vehicle 42, which lifts the bomb cart type vehicle off the transfer platform 40. The electrical rails 50 may be configured in a variety of layouts or configurations. As shown in Figs. 18 and 19, the electrical rails 50 are configured in an X-Y configuration with X-configured rails 52 perpendicularly intersecting or touching a Y-configured rail 54. There may be multiple Y-configured rails 54, and there may be more or less X- configured rails 52 than shown.

[0062] The transfer platform 40 may be directly attached to the gantry crane 20, as shown in Figs. 2, 18, and 19. Alternatively, the transfer platform 40 may be separate and moveable in relation to the gantry crane 20. Both configurations of the transfer platform 40, attached or separate from the gantry crane 20, are compatible with the embodiments of the transfer platform shown in Figs. 2, 18, and 19.

[0063] Fig. 3 depicts the container (C), still on the transfer platform 40, attached to a spreader beam 110. The container (C) is positioned under a cell opening 74A by the bomb cart type vehicle 42 or other platform means. A transfer unit 100 moves along the overhead guide track system and over the corresponding cell opening 74A. The transfer unit 100 then lowers the spreader beam 110 through the cell opening 74A via cables 115 until the spreader beam contacts a top of the container (C). The twist locks then engage the spreader beam 110 secure the spreader beam to the container. Once secured to the container (C), the transfer unit 100 retracts the spreader beam 110 and container off the transfer platform 40; through the cell opening 74 and within the transfer unit.

[0064] # Fig. 4 shows the container (C) fully secured and engaged within the transfer unit 100 of the overhead guide track system. The container (C) is fully held within a volume of the transfer unit 100 to ensure that the transfer unit can move unimpeded along tracks 66, 67 of the overhead guide track system. The transfer unit 100 is preferably positioned on top of the tracks 66, 67. As shown, the transfer unit 100 can move laterally and / or longitudinally along the tracks 66 or 67, to move in an X or Y configuration to an intended destination.

[0065] One such destination for the container (C) is to a storage area 200 beneath the overhead guide track system 60, as shown in Figs. 5 and 6. To store the container (C) in the storage area 200, the transfer unit 100 moves over storage cell opening 75 corresponding to a storage cell 202. Each storage area 200 underneath the overhead guide track system 60 may have multiple storage cells 202. Each storage cell 202preferably has multiple columns and multiple rows of containers (C). Once the transfer unit 100 is in place over the container’s intended destination, the transfer unit places the container via cables 115 and the spreader 110. Once the container (C) is in place in the storage cell 202 as shown in Fig. 6, the twist locksl 16 of the spreader beam 110 are released. The spreader beam 110 is then lifted back to the transfer unit 100 via the cables 115, and the transfer unit 100 moves on to its next task.

[0066] In Fig. 7, the transfer unit 100 moves along the overhead grid guide track system 60 along perpendicularly oriented tracks 66 and 67 such that it moves in a Y pattern in order to move over different storage areas and to different areas of the grid system to pick up or drop off the container (C). The transfer unit 100 in Fig. 7 is shown at an intersection of the overhead grid guide track system 60, which is detailed further herein.

[0067] Figs. 8 and 9 show other destinations for the transfer units 100 and containers (C). In Fig. 8, the transfer unit 100 positions itself over an end cell opening 74A via the overhead grid guide track system 60 and lowers the container downwards toward a truck (T) via cables 115 and spreader beam 110. Once the container (C) is on the truck T, the twist locksl 16 on the spreader beam 110 are released and the spreader beam 110 is retracted back to the transfer unit 100 via the cables 115. The truck (T) is then # free to transport the container (C) to another destination, while the transfer unit 100 moves onto its next destination.

[0068] Fig. 9 shows the transfer unit 100 depositing a container (C) on a rail car (TN). The transfer unit 100 with the container C moves along the overhead grid guide track system 60 and over an end cell opening 74A. There may be two rows of end cell openings 74A such that the containers C may be deposited onto rail cars TN and trucks simultaneously via multiple transfer units 100. Once over the end cell opening 74A, the transfer unit 100 drops the container C downwards toward the rail car TN via cables 115 and spreader beam 110. Once the container C is on the rail car TN, the twist locks 116 on the spreader beam 110 are released and the spreader beam 110 is retracted back to the transfer unit 100 via the cables 115. The train TN is then free to transport the container C to another destination, while the transfer unit 100 moves onto its next destination.

[0069] The storage and distribution system 1 of the present invention is specifically designed to permit immediate transfer of shipping containers C between container ships S and conventional land-based means of transportation such as trains TN and trucks T or between outside temporary or longer storage areas such as one or more warehouse structures, not shown, with no more than one transfer point.

[0070] Importantly, the transfer unit 100 described herein conceivably may further secured and move objects other than containers (C), such as boxes, frames, platforms, baskets, or other three-dimensional structures used to hold, store, contain, and / or move one or more goods or items. Similarly, the storage and distribution system 1 may utilize the transfer units to move and store such objects along the described overhead grid guide track system 60.

[0071] Further embodiments of the storage and distribution system 1 contemplate the transfer of shipping containers from one container ship S to another container ship S. In such an embodiment, containers C would be moved off the first container ship S via gantry crane, onto the transfer platform 40 for pickup by the transfer unit 100 of the overhead grid guide track system 60, moved along the overhead grid guide track # structure, and then deposited onto another ship’s, S’, grid guide track storage system, 60, for transfer to its transfer platform 40 corresponding to the second container ship S’ for pickup by another gantry crane; the second platform, crane, and ship not shown.

[0072] In some embodiments, one or more warehouses may be enclosed by side walls covered by a roof, not shown. In other embodiments, the warehouses may be open and not enclosed by roofing or walls.

[0073] The overhead grid guide track system 60 of the present invention is designed to move containers C efficiently and effectively between all desired locations in a terminal, transfer facility or port setting. The overhead grid guide track system 60 can be as high as the containers can be stacked and cover an entire storage area 200 to store as many containers C as an area can accommodate. As an example, 3,673 forty-foot containers can be stored on four acres, stacked seven containers high, or 4,198 stacked eight containers high. This is based on approximately 8 feet x 40 feet containers (8 feet wide x 40 feet long) with other configurations yielding different numbers.

[0074] As shown in Figs. 1 -9, the overhead grid guide track system 60, or grid system, is specifically designed to permit the simultaneous movement of a plurality of the transfer units 100 between the elevated transfer platform 40, the warehouses or the open storage areas 200, a truck loading / unloading area 63, a railway loading / unloading area 64, additional storage areas 200 or warehouses, and / or a second ship S’. To accomplish this, and referring now to Fig. 13, the overhead grid guide track system 60 includes a first plurality of parallel rails 66 that extend inwardly of the dock side that intersect with a second plurality of parallel rails 67 that are transversely and perpendicularly oriented relative to the first plurality of parallel rails. Together, the first plurality of parallel rails 66 and the second plurality of parallel rails 67 are referred to herein as the X-Y grid system 66, 67. The structure of individual rails of the X-Y grid system 66, 67 will be described in greater detail hereinafter. Because of the intersecting rails of the X-Y grid system 66, 67, the transfer units 100 can move in an X-Y plane to maneuver shipping containers between the various modes of transportation and the storage areas 200 and warehouses. The entire container storage area 200 can be # covered by the overhead grid guide track system 60 so the transfer units 100 can traverse the entire storage area. A four-acre storage area 200 can accommodate ten or more ATUs. As the demand for more container movement speed increases, more ATUs can be added to the grid system 60.

[0075] Moreover, the coverage or footprint of the overhead grid guide track system 60 may vary to fit the needs of the terminal. For instance, sections of rails of the X-Y grid system 66, 67, such as shown in Fig. 7, may be designed to connect different, larger areas of rails. The guide track system 60 of Fig. 8 is also designed in such a way that the transfer unit 100 may easily deposit containers C onto multiple rows of truck loading areas 63 Fig.8 and / or train loading areas 64, Fig. 9, including multiple trains T or trucks TC, or even onto the platform 40 Fig. 4. There are no set configurations of the X-Y grid system 66, 67, which can be designed to meet specific needs and layouts of any given port or distribution center. Additionally, the configuration of the tracks 66, 67 in Fig. 17 represents a prototype of the grid system 60 for testing, along with prototypes of the transfer unit 100.

[0076] The overhead grid guide track system 60 of Figs. 1-5 is formed by vertical steel columns or posts 87 Fig. 13 secured to and supporting a horizontally extending grid frame or support structure 70. The grid frame 70 is secured at a given height above a ground level on which containers C are stored, the given height variable based on the desired level of stacked containers to be stored below the grid frame 60. The first plurality of parallel rails 66 and the second plurality of parallel rails 67 are located and secured on top of the grid frame 70 Fig 13. The grid frame 70 can be made of industry standard materials, including steel I-beams, T-beams, and or box beams. One or more walls 69 Fig. 13 may be present and secured to the steel columns 87 directly or via roof structure 68 secured to upper ends of the steel columns 87. If present, the roof structure 68 must provide enough clearance or height above the tracks 66, 67 for transfer units 100 to move unimpeded between the roof structure and the tracks 66, 77.

[0077] As described, past container storage and distribution systems utilized a simple X- Y configuration for the grid system 60. However, such a system limits movement of # transfer units 100 and can create bottlenecks in movement along the X-Y grid system 66, 67. The present invention preferably utilizes a double X-Y configuration to alleviate such an issue. As shown in Fig. 13, the double X-Y configuration utilized a first plurality of pairs of parallel rails or tracks 76 (each including rail or track 66A and 66B of the first plurality of tracks 66) oriented in a first direction and a second plurality of pairs of rails and tracks 77 (each including rail or track 67A and 67B of the second plurality of tracks 67) transversely and perpendicularly oriented in a second direction relative to the first plurality of parallel rails or tracks, such that each pair of rails or tracks of the first plurality of pairs of parallel rails or tracks is equally spaced from adjacent pairs of rails or tracks of the first plurality of pairs of parallel rails or tracks and each pair of rail or track of the second plurality of pairs of parallel rails or tracks is equally spaced from adjacent pairs of rails or tracks of the second plurality of pairs of parallel rails or tracks.

[0078] Such a configuration creates two types of cell openings in the X-Y grid system 66, 67, as previously described. The first type of cell opening 74 is created by the space between two adjacent pairs of tracks 76 of the first plurality of pairs of tracks 66 and two adjacent pairs of tracks 77 of the second plurality of pairs of tracks 67. The second type of cell opening 75 is created by the space between two adjacent pairs of tracks 76 of the first plurality of pairs of tracks 66 and space between rails or tracks 67A and 67B of one pair 77 of tracks 67A, 67B of the second plurality of pairs of tracks 67. The transfer units 100 lift and deposit containers C through both cell openings 74 and 75. The cell openings 74 are mostly used along ends of the grid system 60, and identified as end cell openings 74A, to pick containers C off the transfer platform 40 and deposit them on trucks T or trains TN. The grid system 60 extends, and preferably aligns, storage cell opening 75 above a periphery of each underlying imaginary or real storage cells 202 within the storage area of the system in such a manner that the transfer units 100 may be directly and selectively aligned above the cell opening to place a shipping container C into a storage cell 202 or elevate a container from a storage cell.

[0079] The grid frame 70 preferably has one or more angled sides 71 to provide space for the transfer platform 40 to be as close as possible to the bottom of the grid frame # while still allowing space for the transfer unit 100 to pick containers C off the receiving platform, as best shown in Fig. 3.

[0080] Each track or rail of the X-Y grid tracks 66, 67 is formed by a flat, horizontal longitudinal member 120 Fig. 14B providing a smooth upper surface and two guards 122 each being vertical members located on opposite lateral ends of the longitudinal member. Each longitudinal member 120 is bolted, welded, or otherwise secured to steel girders or roofing beams of the grid frame 70. Together, the longitudinal member 120 and guards 122 preferably create a substantially U-shaped cross-section along a lateral axis. The term substantially is used in reference to the U-shaped cross-section, as a 90- degree angle is preferably formed between the longitudinal member 120 and each guard 122. However, other angles work, along with curved surfaces between the longitudinal member 120 and guards 122. An inwardly extending lip 124, shown clearly in Fig. 14B, is preferably secured about a free end of each guard 122 to secure the one or more air bearing carriages 108 of each transfer unit 100 within the rails 66, 67. The guards 122 limit and direct lateral movement of the air bearing carriages 108, and correspondingly the transfer unit 100, to follow the length of the longitudinal members 120. Similarly, the lips 124 prevent upward movement of the air bearing carriages 108 out from between the two guards.

[0081] An embodiment of the transfer unit 100 is shown in Figs. 10A-11 . The transfer unit 100 includes a housing formed by a central frame 102 that supports various structures of the transfer unit. The housing also includes a plurality of members 104 all extending in a same direction downwardly from the central frame 102. Preferably, each member 104 of the plurality of members extends downwardly from a corresponding corner of the central frame 102. More preferably, the housing is formed by a rectangular central frame 102 with four members 104, each member of the four members extending from a corresponding corner of the rectangular central frame. One or more support members 106 may be secured to and between two adjacent members 104 to provide stability to the transfer unit 100 and prevent independent movement of the members 104 relative to the central frame. Preferably, the central frame 102, members 104, and # support members 106 form a rectangular cuboid corresponding to a transfer unit cell 107 with large enough dimensions to house a container C.

[0082] A spreader beam 110 is attached to cables 115, which in turn are secured to one or more winding drums 114 powered by one or more hoist motors 112. The cables 115 may further include a pulley system, not shown, having sheaves lined up to a center of each winding drum 114 to maintain vertical. Maintaining vertical, as referred to in this disclosure, means that each set of cables 115 does not create an angle off of 90 degrees between the corresponding winding drum 114 and a corresponding corner of the spreader beam 110. Both the winding drums 114 and the hoist motor 112 are preferably mounted to a shuttle 140 which frames and houses the winding drums 114 and hoist motor 112. Together, the shuttle forms a hoist and motor system with its housed winding drums and hoist motors. The shuttle 140 can be an open frame structure or have one or more closed sides. In the embodiment of Figs. 10A-10E, one hoist motor 112 and two winding drums 114 are provided and secured within one shuttle, with a shuttle provided for each of the two ends of the spreader beam 110. Other numbers and configurations of those structures are possible based on container weight, safety, and power requirements.

[0083] Multiple pinions 146 are attached to each shuttle 140, each pinion attached to the shuttle by a pinion housing 150. A motor, not shown, is preferably provided and housed within each pinion housing 150 to drive and cause the corresponding pinion to rotate. Preferably, the pinions 146 and pinion housings 150 extend downwardly from the shuttle 140. However, the pinions 146 and racks 148 may be otherwise oriented in such a way that they still both interact with each other in a manner to move the shuttle along a length of the rack relative to the transfer unit 100. A rack 148 is provided along a length of the frame 102, and preferably an entire inner length, on each of two opposing sides of the frame. The rack 148 has teeth 149 along an inner surface corresponding to teeth of the pinions 146. In operation, each pinion 146 has teeth that engage an adjacent rack 148 along respective teeth of the rack, and the pinion motors 150 inside

[0084] # the pinion housing 150 act to rotate the pinions against the racks and move the shuttle back and forth along a length of the transfer unit 100.

[0085] Multiple rollers 142 are also attached to the shuttle 140, preferably at least one roller attached along each of two opposing ends of the shuttle. A guide track 144 is provided along a length, and preferably an entire inner length, of the frame 102 along opposing sides of the frame. The rollers 142 are configured to be secured to the guide track 144 and rotationally translate along a length of the guide track, which in turn allows the shuttle 140 to move back and forth along the guide track and rack 148. Preferably, each roller has lips defining a central groove around the circumference of the roller. When secured to the guide track 144, the guide track fits within the groove of the roller 142 and the lips of each roller oriented on opposing sides of the guide track. The rollers 142 further provide vertical support to the shuttle 140 to prevent the shuttle from being pulled downward off the guide track 144 and rack 148. The racks 148 and pinions 146 provide horizontal support and help keep the rollers 142 aligned on respective tracks 144. The rollers 142 especially must be capable of withstanding a substantial load when containers C are secured to the spreader beam 110, and are made with materials and in a manner as known in the art.

[0086] In operation, the shuttles 140 preferably move laterally and in unison with the ends of the spreader beam 110 ensure that the cables 115 maintain vertical. In other words, shuttles 140 move to ensure that the cables 115 are parallel with members 104 and perpendicular to frame 102, as the spreader beam 110 can expand and contract in length to secure containers C of varying lengths. Otherwise, the cables 115 experience additional strain forces that can jeopardize the safety of the container C and the transfer unit 100. Further, sensors, not shown, may be attached or in communication with the winding drums 114, hoist motors 112, and / or cables 115 to detect and automatically adjust tension in the cables to achieve a tension balance when a container C attached to the spreader beam 110 has an unevenly distributed load.

[0087] The spreader beam 110 structure of the present invention provides several benefits to prior spreader beam configurations. These benefits are provided by the # spreader beam 110 having a four-corner configuration versus the central cantilever configuration of past spreader beams. In spreader beam 110, the cables 115 securing the spreader beam to the transfer unit 100 are decentralized and preferably one cable of the cables 115 is located at each of four corners of the spreader beam corresponding to each of four corners of a container (C). This configuration transfers weight and force of a container (C) secured to the spreader beam 110 to the wires or cables 115. In known spreader beams with a centralized cantilever system, the cables converged at a cantilever centrally located on the spreader beam. This structure puts immense force on the middle of the spreader beam. Due to this force, the middle of the spreader beam had to be reinforced to prevent the spreader beam from buckling. Since the spreader beam 110 decentralizes these forces to its four corners, the reinforced middle is no longer needed and drastically reduces the weight of the spreader beam. The relative light weight of the spreader beam 110 further reduces power output requirements of the transfer unit 100 and overall system 1 .

[0088] The rack 148 and pinion 146 system of the transfer unit 100 assists in maintaining the decentralized forces of the spreader beam 110 by maintaining vertical, or perpendicular cables 115 relative to a length of the spreader beam. As the transfer unit 100 is designed to move containers (C) or other structures of various lengths, both ends of the cables 115 along the spreader beam 110 and the winding drums 114 must be movable. The rack 148 and pinion 146 system allows upper ends of the cables to be movable, while the retraction and extension of the spreader beam 110 allows lower ends of the cables to be moveable.

[0089] The outputs from the hoist motors 112 may be connected through power splitters to one or more winding drums 114, which may include one or more winding drums 114. The cables 115 are secured to and wound about the winding drums 114, and a lower end of each cable is fixed to the spreader beam 110. As the spreader beam 110 is lowered toward an underlying shipping container C, by activation of the hoist motors 112, the spreader beam will engage about an upper periphery of the shipping container, after which locking mechanisms 116 located about each corner of the spreader beam # are automatically tripped to engage the lock boxes of the containers. A flipper 118 at each corner of the spreader beam 110 corresponding to each corner of the container C extend downwardly from the spreader beam and set an outer boundary corresponding to a minimum space needed for the container be lifted into the transfer unit cell 107. The shipping container can then be elevated to a position entirely within the transfer unit cell 107, as shown in Figs. 10A-10C. In this position, the transfer unit 100 and container C can be moved along the railings 66, 67 to store the shipping containers as desired and as shown in Figs. 5-9.

[0090] An air bearing carriage 108 is attached to the free end of each member 104 opposite to the central frame 102. The transfer unit 100 also includes one or more air compressors 127 and air tanks 128 to supply pressurized air to each air bearing carriage 108. Each air bearing carriage 108 is connected to an air supply line, not shown, extending through the frame 102 and a corresponding member 104 and operably connected to the air tank 128 holding pressurized air, the air being pressurized by the air compressor 127. As explained further herein, each air tank 128 supplies pressurized air to one or more air bearing carriages 108 to vertically lift the transfer unit 100 off longitudinal member 120 for lateral movement along the X-Y grid system 66, 67.

[0091] The bomb carts type vehicle 42 used to move containers C on the transfer platform 40 between the port cranes 20 and grid system 60 may use similar air bearing carriages 108, as well as an onboard air tank 128 and air compressor 127, not shown.

[0092] Lateral movement of the transfer unit 100 along the X-Y grid system 66, 67 is achieved via motorized movement means, such as motorized wheels 130. The number and position of the motorized wheels 130 may vary, but in any scenario will allow the transfer unit 100 to move in both the X direction and the Y direction of the X-Y grid system 66, 67. The motorized wheels 130 may be configured and positioned to pull the transfer unit 100, push the transfer unit, or a combination of both. The motorized wheels 130 may be further configured to descend and retract vertically toward and away from the free end of the members 104 having attached the air bearing carriages 108. In the transfer unit 100 embodiment of Figs. 10A-10E, the motorized wheels 130 are secured # to support members 106. Alternatively, the motorized wheels can be secured to member 104 or air bearing carriages 108 or other structures of the transfer unit. For example, when the motorized wheels 130A in Fig. 10A are in the movement configuration, (are descended to contact the longitudinal member 120) for movement of the transfer unit 100 longitudinally in the fore or aft directions, the motorized wheels 130B in Fig.10B are in the retracted configuration where the wheels are lifted off the lateral member 120. Conversely, when the motorized wheels 130B in Fig.10B are in the movement configuration (are descended to contact the lateral member 120), for movement of the transfer unit laterally in the fore or aft directions, the motorized wheels 130A in Fig.l OA are in the retracted configuration where the wheels are lifted off the longitudinal member 120. The means for descending or retracting may vary including in a linear, radially or a combination of both. Each motorized wheel 130 preferably contains its own corresponding motor.

[0093] Power to the hoist motors 112, air compressor 127, motors 130 of the motorized wheels 130A-B, and other devices associated with each of the transfer units 100 may be provided by onboard rechargeable batteries, not shown. The hoist motors 112 may be two 75 horsepower motors. The cables 115, via the hoist motors 112, may lift fully loaded containers at a rate of up to approximately 75 feet per minute and may operate at up to 112 feet per minute with no load.

[0094] Each transfer unit 100 is designed to raise and lower at least one shipping container C via a spreader beam 110 having locking mechanisms 116, the spreader beam suspended from, and vertically movable by, cables 115 via sheaves (not shown) attached at each of the four corners of the spreader beam 110. The cables 115 are secured to winding drums 114 mounted on the trolley 102. Each cable 115 passes around each sheave and goes back up, vertically, to a hoist, not shown. There is a hoist for each cable 115 at each corner of the spreader beam 110. When the transfer unit 100 picks up a container C with the spreader beam 110, the spreader beam is pulled up to the transfer unit adjacent to the central frame 102 unit. The spreader beam 110 and container C are pulled up between the air bearing carriages 108 and members 104 # through a bottom plane of the transfer unit cell 107. The container C must fit within the transfer unit cell 107 such that a bottom of the container clears and is able to move above and over the guards 122 of rails 66, 67 before the transfer unit is able to safely move along the X-Y grid system 66, 67. When the spreader beam 110 is not attached to a container C and the transfer unit 100 moves, the spreader beam 110 is pulled up and locked to the transfer unit within the transfer unit cell 107.

[0095] Fig. 16 shows a preferred spreader beam 110 with cables 115 secured about its four corners. The spreader beam 110 is designed to automatically lock to a corresponding shipping container with the locking mechanisms 116, one locking mechanism preferably located at each corner and / or end of the spreader beam and being compatible with all conventional shipping containers. The spreader beam 110 may be extendable to be usable to lift both 20-foot, 40-foot and 45-foot containers. The spreader beam 110 may include movable portions 110A and 110B, to allow a shortening or lengthening of the spreader beam to accommodate containers C with different lengths. The portions 110A and 110B may telescope within each other or within a central portion 111 of the spreader beam.

[0096] Preferably, the locking mechanisms 116 are located on spreader beam 110 at each of four corners of the spreader beam. The locking mechanism is preferably of the twistlock type. Other types of conventional locking mechanisms for safely and securely attaching the spreader beam 110 to a shipping container may be used. Further, the spreader beam 110 may include remote controlled locking mechanisms such as twist locks or other workable mechanisms for securing containers C.

[0097] Figs. 11A-11 B show an embodiment of an air bearing carriage 108 of the present invention. Each air bearing carriage 108 includes a housing 93 Fig. 11 B secured to a corresponding free end 104A of a member 104 of the transfer unit 100. The housing 93 has a bottom surface 90 being the bearing face. A raised lip 91 may extend along the periphery of the bottom surface 90. The raised lip 91 is preferably ceramic plating but can be any other durable material with a similarly low co-efficient of friction. The bottom surface 90 of the air bearing carriage 108 includes air pad surfaces 92 having a plurality # of holes 94 fluidly connected to the air supply line through which air is forced out. Pressurized air is supplied by the air compressor 127 and / or air tank 128 via the air supply line down the member 104, into the housing 93 and out of the holes 94 of the air bearing carriage 108, as represented by arrows in Fig. 11 B. The supply of air through each air bearing carriage 108 may be independently controllable. In other embodiments, each air bearing carriage 108 may include multiple air pad surfaces 92, for each of which the supply of air is independently controllable. Therefore, one or more of the air pad surfaces 92 may be supplied air while one or more air pad surfaces are not supplied air simultaneously on the same air bearing carriage 108 or across multiple air bearing carriages 108. A view of the air bearing carriage 108 along the bottom surface 90 is provided in Fig. 11 B.

[0098] In operation, the air compressor 127 and / or air tank 128 mounted on the central frame 102 of the transfer unit 100 supplies pressurized air into an air supply line. The air supply line, not shown, extends along each member 104, preferably inside but alternatively outside, and into the hollow housing 93 of the air bearing carriage 108 and downwardly out of the plurality of holes 94 in the air pad surfaces 92.

[0099] Figs. 12A and 12B show alternative embodiments of the air bearing carriage 108 having and linear induction motor system 160, including a rotor or conductor 164, or secondary portion, secured along the bottom surface 90 of the air bearing carriage and a stator 162, or primary portion, installed along the length of each longitudinal member 120 of an alternative embodiment of the X-Y grid system 66, 67. Together, the rotor 164 and stator 162 form a linear induction motor system 160 that is used to move the transfer unit 100 laterally along the X-Y grid system 66, 67. The linear induction motor system can be used instead of motorized wheels 130 or along with motorized wheels to move the transfer unit 100.

[0100] Each air bearing carriage 108 of the embodiments of Figs 12A and 12B, and the corresponding transfer unit 100, is moved along a length of each track 66, 67 by a linear induction motor system 160. In an alternative embodiment of the X-Y grid system 66, 67, the stator 162, or primary portion of the linear induction motor system 160, is fixed to # or within each track 66, 67 and extends along an upper surface of each track in both longitudinally extending tracks 66 and transversely extending tracks 67. The rotor 164, the movable secondary portion of the linear induction motor system 160, is provided along the bottom surface 90 of each air bearing carriage 108 of the transfer unit 100. The primary portion 162 creates a linear magnetic field through various generated electric currents supplied to primary portion. Therefore, the stator 162 is also attached to a source of electricity, not shown. The secondary portion 164 attached to each air bearing carriage 108 contains magnets which interact with the linear magnetic field produced by electricity supplied to the corresponding primary portion 162 to move all rotors 164 of the transfer unit 100 in the same direction along the longitudinal member 120. The electrical current and resulting linear magnetic field produced by the primary portion 162 of the linear induction motor system 160 can be reversed to move the secondary portions 164, and thus the transfer unit 100, in the opposite direction along the hollow longitudinal members 120. The configuration of the stators 162 and rotors 164 allows the linear induction motor system 160 to move the transfer unit 100 in an X- Y grid along the longitudinal members 120 of the X-Y grid system 66, 67.

[0101] The bottom-up views of Figs. 12A and 12B the linear induction motor system 160 and air bearing carriage 108 with the longitudinal member 120 removed to more clearly see the configuration of the rotor 164 and stator 162.

[0102] In Fig. 12A, the stator 162 and rotor 164 are centrally located on both the air bearing carriage 108 and longitudinal member 120, respectively. In this embodiment, the rotor 164 is secured in the center along the bottom surface 90 of the air bearing carriage 108 and surrounded by air pad surfaces 92 and holes 94. The stator 162 extends along a central portion of the longitudinal members 120 in both the X and Y directions of the X-Y grid system 66, 67. Alternatively, the stator 162 may extend along an entire width of each longitudinal member 120. When the transfer unit 100 is secured to the X-Y grid system 66, 67, air flowing downwardly from the air bearing carriage 108 lifts the transfer unit upwards off of the longitudinal member 120, and the linear

[0103] # induction motor system 160 moves the transfer unit 100 laterally in the X or Y direction, as conventionally known in the art.

[0104] In Fig. 12B, the stator 162 and rotor 164 are peripherally located on both the air bearing carriage 108 and longitudinal member 120, respectively. In this embodiment, the rotor 164 is located on the raised lip 91 of the air bearing carriage 108 such that the rotor surrounds the air pad surfaces 92 and holes 94. The rotor extends along either side of each longitudinal member 120 in both the X and Y directions of the X-Y grid system 66, 67. Alternatively, the stator 162 may extend along an entire width of each longitudinal member 120. When the transfer unit 100 is secured to the X-Y grid system 66, 67, the air bearing carriage 108 lifts the transfer unit upwards off of the longitudinal member 120, and the linear induction motor system 160 moves the transfer unit 100 laterally in the X or Y direction, as conventionally known in the art.

[0105] The tracks 66, 67 that form the grid system 60 include longitudinally extending tracks 66 and transversely extending tracks 67 that are oriented at generally right angles with respect to one another to allow the transfer unit, via the air bearing carriages 108 to move in in the X-Y directions, as shown in Fig. 13. Each air bearing carriage 108 fits between respective guards 122 and horizontally on top of the longitudinal member 120 of the corresponding track 66 or 67. The inwardly extending lip 124 on each guard 122 prevents the air bearing carriage 108 from being lifted out from between each guard. When pressurized air is supplied in a constant manner to the air bearing carriage 108, the air is forced downward against the longitudinal member 120 of track 66 or 67. The resulting force then pushes the air bearing carriage 108, and transfer unit 100 upwards and away from the longitudinal member 120 such that the transfer unit 100 floats slightly above the longitudinal member and between the guards 122. Preferably, all air bearing carriages 108 of a transfer unit 100 are simultaneously lifted off the longitudinal member 120. The movement means, such as the motorized wheels 130, are then engaged against the longitudinal member 120 for lateral movement of the transfer unit 100. As the transfer unit 100 is suspended slightly above the longitudinal member 120, less lateral force is needed from the motorized wheels # 130 to achieve lateral movement of the transfer unit 100 even when burdened with a container C.

[0106] The raised lip 91 of the air bearing carriage 108 is shaped to help direct air flow to achieve lift of the air bearing carriage against the longitudinal member 120. The raised lip 91 extends completely around the periphery of the bottom surface 90 of the air bearing carriage 108 to help force the pressurized air downward and limit lateral escape of pressurized air.

[0107] The surface of the raised lip 91 is ideally covered in or made from a low-friction material. Preferably, the surface of the raised lip 91 and material layer of the longitudinal member 120 are made from the same low-friction material. Should the air bearing carriage 108 lose air flow for some reason, e.g., mechanical failure or loss of power, the low-friction material of surfaces will allow the air bearing carriage to slide along the surface of the longitudinal member 120 more easily. Preferably, the surfaces of the air bearing carriage 108 and longitudinal member 120 are made from ceramic materials.

[0108] To better understand the improved efficiencies of the double rail sections 76, 77 Fig. 13, the overall footprint of the grid system 60 and the grid cell openings 74, 75 spacing should be considered. First, the footprint of the guide track system 60, as seen in Fig. 1 , is identical to past guide track systems without double rail sections. In other words, the guide track system 60 with the addition of the double rail sections 76, 77 takes up the same amount of space as previous guide track systems with the same number of grid cell openings 74 and 75, but drastically improves efficiency of the system. The double rail sections 76, 77 allow transfer units 100 in adjacent cells 74, 75 to simultaneously operate and traverse the grid system 60.

[0109] In an overhead grid guide track system 60 without double rail sections 76, 77, but the same number of cell openings 74, 75, transfer units 100 could not operate in adjacent grid cells, as the air bearing carriages 108 cannot share the same box beam. Further, one transfer unit 100 would need to always maintain at least one grid cell opening 74, 75 space in between another transfer unit while travelling. Such a configuration can easily create a bottleneck in maneuvering transfer units 100 around # each other, as well as reduce the total number of transfer units that could practically coexist on the same grid system 60.

[0110] The tracks 66, 67 of the double rail section 76, 77, can be positioned immediately next to each other or may have a space between. In other words, the distance between the tracks 66, 67 of a double rail section 76, 77. However, to maximize the number of transfer units 100 and area covered by the guide track system 60, it is preferable that the distance be as small as possible and at least smaller than the width of a transfer unit 100. Even more preferably, the distance is 10 cm or less.

[0111] Further, the grid track system 60 may include a combination of double rail sections 76, 77 and single sections of rails 66, 67. The double rail sections 76, 77 are not ideally placed along the periphery of the grid track system 60, as only one carriage transfer unit 100 can move along the periphery of the grid track system at a given section of tracks.

[0112] As conventionally known, some embodiments the transfer unit 100 may be modified to permit the spreader beam 110 to be rotated through 360° to be able to universally adjust the orientation of a container C relative to a receiving surface, such as a trailer bed or flat car bed. To permit such movement, a lower platform may be connected below and to central frame 102 by way of a trunnion assembly. In this embodiment, the two hoist motors 112 and pairs of winding drums 114 are mounted to the lower platform. The trunnion assembly includes a circular rack having teeth that mesh with teeth of a beveled drive gear rotated by a trunnion motor mounted on the platform. The trunnion motor includes a reversible output drive shaft so that the lower platform may be rotated both clockwise and counterclockwise. The trunnion motor may also include an anti-back drive gear to lock the platform in position relative to the frame 102 whenever the trunnion motor is not being driven.

[0113] The grid system 60 and transfer units 100 of the present invention may be fully automated and interfaced with an inventory control system as conventionally known so that the location of each container C within the system is always known. By way of example, bar codes, radio frequency identification (RFID) tags or other identification # means may be placed on each container C and on each transfer unit 100. An inventory management center is provided that includes a radio signal transmitter. Utilizing directional frequency transmissions, remote tags are located within the system. The tags not only include information as to the identity of the container C but may include information concerning the contents, the identity of the shipper and of the receiver as well as any other information that may be of interest to port or transportation personal, government authorities and others. Once a transfer unit 100 is secured to a container C through the spreader beam 110, a control computer within the management center will follow the movement of both the container and the transfer unit. In some instances where it is known that a particular container being offloaded from a container ship is to be transported by an identified ground transporter, such as a truck T or train TN, the container may be moved directly from the ship or transfer platform 40 to an awaiting truck or rail car or moved to a loading dock area where the contents of a container may be separated for shipment in smaller volumes. In instances where containers are to be offloaded from a ship or from a ground transportation source and placed into storage for future shipment, information is communicated to the transfer units 100 to move the containers to specific locations within the system, such as a given stacking area within the open storage area(s) or the warehouse(s).

[0114] In addition to the foregoing, in some embodiments and as conventionally known, the transfer units 100 being remotely controlled may include transceivers for electronically communicating with a terminal operating system or inventory management center of the port. In addition, the terminal operating system may include a transfer unit control system for specifically controlling the operation and movement of the transfer units 100 operating on the grid system 60. Each transfer unit 100 may receive instructions and / or tasks from the terminal operating system or the transfer unit control system and then confirm instructions and / or that the task was completed to the terminal operating system or the transfer unit control system.

[0115] # In other instances, the transfer units 100 may be controlled from a remote location using radio frequency technology, Global Positioning Technology (GPS) and the like.

[0116] In addition to remote communications control of the movement and location of the transfer units 100 and containers C of the invention, sensors and the like may be affiliated with the motors, winches, drive gears and the like of the invention to monitor the exact location of the vehicles and containers, as conventionally known. Digital input from drive motor rotations and registration at digitized check points along the grid system 60 or at each storage cell 202 location within a ship S or within a storage area 200 or warehouse may also provide information relating to the movements of the transfer units 100 within the guide track system 60. The hoist motors 112 may also have digitized features for determining the exact elevation and relationship of the transfer beams 110 to each transfer unit 100 when raising and lowering a container C. Drive motors 112 may be controlled by master encoders and synchronizing slave encoders with X-Y position sensors located within the grid track system for position identification and / or verification.

[0117] Each transfer unit 100 may optionally be equipped with a variety of sensors to properly function in conjunction with other transfer units on the grid system 60, the transfer platform 40, trucks T, and trains TN. Each transfer unit 100 may include optical character recognition (OCR) sensors for identifying specific containers C. Additionally, the transfer units 100 may each include GPS sensors for determining their location along the grid system 60. Next, the transfer units 100 may be equipped with lasers or similar sensors for alignment with surrounding structures. The transfer units 100 may also be equipped with impact sensors to avoid colliding with surrounding structures. The transfer units 100 may be equipped with weight sensors to detect weight of container C contents to prevent overloads and counterbalance weight. Lastly, the transfer units may include RFID sensors for reading RFID tags attached to containers C.

[0118] Additional sensors may be placed throughout the storage and distribution system 1 to further control and improve transportation of containers. Sensors may be placed on # the spreader beam 110 or transfer unit 100 to detect if the locking mechanisms 116 are not removed prior to leaving a landing position. Likewise, sensors may be placed on the port crane 20 to detect if the locking mechanisms 116 are attached to the container C prior to leaving a ship S for transport to the transfer platform 40. The transfer platform 40 may have sensors to detect if a container C positioned on the transfer platform is not moved before a next container arrives on the transfer platform.

[0119] The storage and distribution system 1 may also include sensors to detect a full column to alert a transfer unit control system and terminal operating system, sensors to alert the transfer unit control system that two or more transfer units 100 are on a collision path, sensors to ensure transfer units 100 are properly aligned at intersections to change direction or to deliver or retrieve a container C, and sensors to ensure a container is properly aligned with a pickup position on transfer platform 40 for the transfer platform pickup.

[0120] As conventionally known for security purposes, before the containers C are allowed to be placed into storage or moved from one form of transport to another, the containers are moved adjacent one of the scanning devices at which time the contents of the containers are scanned and compared or matched against computerized bills of lading to verify the contents of the containers and to prevent the movement of illegal or hazardous goods and / or devices. As the scanners are located at elevated locations along the grid track system, the containers do not have to be cyclically raised and lowered. The overhead grid guide track system is specifically designed to eliminate repetitive container transfers between numerous container handlers and to minimize vertical container movement to reduce the time of movement of the containers within the system from one point to another.

[0121] In the event the contents of a scanned container are suspicious, the port system of the invention may also include an inspection station as conventionally known where a questionable container can be placed, and the contents thereof inspected by port officials. Once a container is cleared by inspection, the container may be transferred to storage or to an appropriate transport vehicle or ship.

[0122] # Utilizing the system of the invention, a designated container may be automatically located within a warehouse, storage area or ship’s hold and containers above the designated container may be moved appropriately and, thereafter, relocated once the designated container has been retrieved utilizing the transfer units and their hoist mechanisms.

[0123] Once a designated container is located on board a ship it may be selectively elevated and positioned for retrieval from the hold utilizing one of the transfer vehicles associated with the bridge crane as previously described. Loading of the ship’s hold can also be fully automatic with each container being placed at a predetermined location within the hold as containers that are placed on the elevated transfer platform are loaded into the ship’s hold.

[0124] Using the systems of the invention, it is envisioned that ships can be loaded and unloaded simultaneously to reduce the time a ship must remain at dockside almost in half. Also, multiple transfer units 100 can pre-stage shipping containers in such a way they are positioned closest to their outbound area (truck, rail, ship) in predetermined order to expedite loading onto the mode of transportation (truck, rail, ship). The transfer units 100 can be off lined in the event of breakdown, while the other transfer units continue to transfer the shipping containers. Additionally, the storage area 200 can be divided into an inbound area in the middle, which is empty initially, while the outbound containers are pre-staged to be worked from the inside out, towards the outside of each pre-stage area for truck T, train TN, and ship S movement.

[0125] An alternate embodiment of the storage and distribution system 1 may also include solar panels 300 installed on the roof structure 68, as shown in Figs. 15A-15B. The solar panels may be used to supply electrical energy for powering the system, more specifically the transfer units 100 and grid system 60. The system 1 otherwise operates as previously described.

[0126] The foregoing description of the preferred embodiment of the invention has been presented to illustrate the principles of the invention and not to limit the invention to the

[0127] # embodiment illustrated. It is intended that the scope of the invention be defined by all the embodiments encompassed within the following claims and their equivalents.

[0128] #

Claims

WE CLAIM:1 . A shipping container storage and distribution system, comprising: an overhead grid guide track structure including a plurality of tracks extending transversely with respect to one another in an intersecting X-Y pattern; at least one transfer unit moveably mounted to and positioned above the grid guide track structure and secured within at least two spaced and parallel first tracks of the plurality of tracks when moving in a first direction and at least two spaced and parallel second tracks of the plurality on the top surface of box beams, I-beams, T- beams or the like when moving in a second direction transverse to the first direction; each transfer unit of said at least one transfer unit having a plurality of air bearings secured within the grid guide track structure to lift the transfer unit relative to the plurality of tracks; and each said transfer unit of said at least one transfer unit having a horizontal movement means configured to move each said transfer unit along said plurality of tracks in said first direction and said second direction.

2. The shipping container storage and distribution system of claim 1 , further comprising a transfer platform attached or synchronized with a ship-to-shore crane; and a bomb cart type vehicle upon which a container from the ship-to-shore crane is placed and transferred to the overhead grid guide track structure.

3. The shipping container storage and distribution system of claim 1 , wherein each said transfer unit of said at least one transfer unit is supported by air bearings and driven in a horizontal direction by electrically or pneumatically actuated wheels or by linear induction motors.

4. The shipping container storage and distribution system of claim 2, wherein the bomb cart type vehicle is supported on air bearings and electrically or pneumatically driven by #wheels or linear induction motors to move the bomb cart type vehicle from a location where the ship-to-shore crane delivers the container from a ship to underneath the overhead grid guide track structure.

5. The shipping container storage and distribution system of claim 4, wherein each said transfer unit of said at least one transfer unit includes two shuttles secured to a central frame of the transfer unit and a spreader beam, the spreader beam being expandable or retractable to align with four corners of of the container whereby the two shuttles vertically align cables connecting the spreader beam and the two shuttles when the spreader beam is attached to the container at four upper corners of the container.

6. The shipping container storage and distribution system of claim 5, wherein each of the two shuttles is configured such that it can move longitudinally back and forth within a central frame of the transfer unit to position the cables attached to the spreader beam.

7. The shipping container storage and distribution system of claim 5, wherein each of the two shuttles is configured such that it can move longitudinally back and forth within a central frame of the transfer unit to position the container when attached to the spreader beam.

8. The shipping container storage and distribution system of claim 5, wherein the two shuttles are movable with respect to the central frame when the spreader beam is secured to the container to maintain a 90-degree angle between cables securing the two shuttles to the spreader beam and the container.

9. A transfer unit, comprising: a housing having a central frame and a plurality of vertical members extending all in a same direction from the central frame; one or more air compressors secured to the central frame;two shuttles secured to and movable relative to the central frame, each shuttle of the two shuttles having shuttle frame securing a hoist and motor system, the hoist and motor system further comprising: one or more hoist motors secured to the shuttle frame; one or more winding drums secured to the shuttle frame and operably connected to and rotatable by said one or more hoist motors; and one or more cables attached to each said one or more winding drums, the one or more cables extendable and retractable relative to the a corresponding shuttle of the two shuttles; and a spreader beam secured at each of four corners of the spreader beam to said one or more cables of each shuttle of the two shuttles; an air bearing carriage being secured to an end of each member of said plurality of vertical members of the central frame, the air bearing carriage having a bearing housing with a plurality of openings along a bottom surface of the bearing housing, the one or more air compressors configured to supply pressurized air to the bearing housing via a corresponding air shaft oriented in a corresponding member of the plurality of members such that the pressurized air is forced out of the plurality of openings along the bottom surface of the air bearing housing.

10. A method of transporting a container, comprising: a) positioning a container underneath an open cell of an overhead grid system; b) picking up the container with a transfer unit of the overhead grid system; c) moving the container to a secondary open cell of the overhead grid system via the transfer unit; and d) depositing the container at a secondary location via transfer unit.11 . The method of claim 10, wherein the overhead grid system further comprises: an overhead grid guide track structure having a plurality of tracks extending transversely with respect to one another in an intersecting X-Y pattern;at least one transfer unit moveably and securely mounted to the grid guide track structure such that each at least one transfer unit is moveable back and forth along a first axis of movement and back and forth along a second axis of movement being perpendicular to the first axis of movement; each transfer unit of said at least one transfer unit having a plurality of air bearings secured to the grid guide track structure to lift the transfer unit relative to the plurality of tracks; each said transfer unit of said at least one transfer unit having a lateral movement means configured to move each said transfer unit along said plurality of tracks in said first axis of movement and said second axis of movement.

12. The method of claim 11 , wherein each said transfer unit of said at least one transfer unit includes two shuttles secured to a central frame of the transfer unit and a spreader beam, the spreader beam being expandable or retractable to align with four comers of the container whereby the two shuttles vertically align cables connecting the spreader beam and the two shuttles when the spreader beam is attached to the container at four upper comers of the container.

13. The method of claim 11 , wherein each of the two shuttles is configured such that it can move longitudinally back and forth within a central frame of the transfer unit to position the cables attached to the spreader beam.

14. The method of claim 11 , wherein each of the two shuttles is configured such that it can move longitudinally back and forth within a central frame of the transfer unit to position the container when attached to the spreader beam.

15. The method of claim 11 , wherein the two shuttles are movable with respect to the central frame when the spreader beam is secured to the container to maintain a 90- degree angle between cables securing the two shuttles to the spreader beam and the container.

16. The method of claim 11 , wherein each said transfer unit of said at least one transfer unit is supported by air bearings and driven in a horizontal direction by electrically or pneumatically actuated wheels or by linear induction motors.

17. The method of claim 10, further comprising a transfer platform wherein the container is positioned on the transfer platform, and both the container and the transfer platform are positioned underneath the overhead grid system prior to step a).

18. The method of claim 17, wherein a bomb cart type vehicle is moveable on top of the transfer platform, and the container is placed on top of the bomb cart type vehicle such that the bomb cart type vehicle moves the container underneath the open cell of the overhead grid system.

19. The shipping container storage and distribution system of claim 18, wherein the bomb cart type vehicle is supported on air bearings and electrically or pneumatically driven by wheels or linear induction motors to move the bomb cart type vehicle from a location where the container is first deposited onto the transfer platform to underneath the overhead grid system.

20. The method of claim 10, wherein the transfer unit is secured within at least two spaced and parallel first tracks of a plurality of tracks of the overhead grid system when moving along an X-axis and at least two spaced and parallel second tracks of the plurality of tracks when moving along a Y-axis, the X-axis and Y-axis being transverse to each other.21 . The method of claim 10, wherein, before step a), the container is removed from a cargo ship via a port crane.

22. The method of claim 10, wherein the secondary location is a storage area, on a train car, or onto a truck.

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