Storage system and method for automatically operating such a storage system

Abstract

The invention relates to a storage system (1) for storing piece goods (S), comprising a plurality of rack aisle units (2) which are arranged next to one another and each of which has at least one automated transport vehicle (7) for storing and retrieving piece goods (S) in the storage racks (3) and a lifting device (8) for transferring the at least one transport vehicle (7) between driving levels and a transfer level; a maintenance workstation (WAP); and at least one maintenance vehicle (9) for transporting the transport vehicle (7) between the lifting device (8) and the maintenance workstation (WAP). The storage system (1) comprises a safety zone (SZ) which extends over the rack aisle units (2) and in which the lifting devices (8) of the rack aisle units (2) are provided, the maintenance workstation (WAP) is outside the safety zone (SZ), and the maintenance vehicle (9) can drive into and / or out of the safety zone (SZ) via a passage. The invention further relates to a method for operating such a storage system, to a rack aisle unit for a storage system, and to a method for determining the need for maintenance of a transport vehicle.

Description

[0001] STORAGE SYSTEM AND METHOD FOR AUTOMATED OPERATION OF SUCH A STORAGE SYSTEM

[0002] The invention relates to a storage system according to the preamble of claim 1 and to a method for the automated operation of such a storage system according to the preamble of claim 39.

[0003] Furthermore, the invention relates to a racking unit according to the preamble of claim 18 and to a method for determining the need for maintenance of a transport vehicle that can be moved in such a racking unit according to the preamble of claim 45.

[0004] Storage systems with at least one racking unit in which transport vehicles move on several levels and are transferred between these levels by means of lifting devices, as well as methods for the automated operation of such storage systems, are known from the prior art.

[0005] For example, WO 2012 / 106746 discloses a storage system with a racking unit at the end of which a lifting device is provided for transferring transport vehicles between driving levels. The lifting device is located in a safety zone enclosed by a safety fence. The transport vehicles can be serviced directly at the lifting device or transported from the lifting device to a maintenance workstation by a forklift.

[0006] However, these known systems have limitations regarding maintenance logistics, plant availability, and safety.

[0007] One object of the invention is to provide an improved storage system and an improved method for the automated operation of the storage system. Furthermore, it is an object of the invention to provide an improved racking aisle unit for such a storage system and an improved method for determining maintenance intervals. In particular, highly automated operation, improved maintenance logistics, and particularly high system availability, as well as a safety-optimized structure, are to be achieved through a common safety zone with, in particular, multiple lifting devices.The problem is solved by a storage system of the type mentioned above, which includes a safety zone surrounded by a boundary, in particular defined by the system, which extends over the several adjacent racking units and in which the, in particular several, lifting devices of the racking units are arranged, in particular functionally integrated, wherein the maintenance workstation is located outside the safety zone and the boundary has a passage passable by the at least one maintenance vehicle, through which the at least one autonomously moving maintenance vehicle can drive into and / or out of the safety zone.

[0008] By positioning the access route outside the safety zone and allowing interaction with autonomously moving maintenance vehicles, it is possible to avoid the need for personnel to enter the safety zone. This can lead to increased workplace safety and exceptionally high plant availability. The combination of these features, in particular, enables a clear separation of maintenance and operational areas and improves maintenance logistics through centralized accessibility.

[0009] A racking aisle unit comprises at least one automated transport vehicle for storing and retrieving general cargo from the storage racks. It is advantageous if a racking aisle unit includes several automated transport vehicles, each for storing and retrieving general cargo from the storage racks.

[0010] Furthermore, the problem is solved by a method for operating such a storage system of the type mentioned above, which comprises the following steps: i) providing an autonomously movable maintenance vehicle at the lifting device, ii) transferring a transport vehicle requiring maintenance from its respective driving level to a height level of the transfer level using the lifting device, and iii) transporting the transport vehicle from the lifting device to the maintenance workstation using the maintenance vehicle, the maintenance vehicle leaving the safety zone via the passage. A particular advantage of the invention is that several rack aisle units, and thus also several lifting devices, can be secured by a common safety zone, resulting in reduced construction and operational effort, since only one safety zone needs to be established and / or monitored.Since the transport vehicles are essentially moved away from the multiple lifting devices by autonomously moving maintenance vehicles, it is not necessary for personnel to enter the safety zone during regular operation, and therefore the lifting devices do not need to be switched off temporarily. This results in both a high level of occupational safety and a particularly high availability of the storage system.

[0011] The (shared) safety zone is therefore not temporary or dependent on individuals, but an integral part of the storage system. By positioning the access road outside the safety zone and allowing interaction with autonomously moving maintenance vehicles, it is possible to avoid the need for personnel to enter the safety zone. This can lead to increased workplace safety and exceptionally high system availability.

[0012] The transport vehicle can be provided at the maintenance workstation and serviced, for example, by a person or a maintenance robot located at the workstation. For this purpose, a test bench, such as a mobile one, can be provided at the maintenance workstation.

[0013] The at least one autonomously moving maintenance vehicle can be designed, for example, as a so-called AGV ("autonomous guided vehicle"), which is guided by waymarkers arranged in the warehouse system, or as a so-called AMR ("autonomous mobile robot"), which can navigate autonomously in the warehouse system, for example on the basis of map data stored in a memory of the industrial truck.

[0014] At least one autonomously moving maintenance vehicle can travel on one floor of the storage system. Therefore, in practice it is also referred to as a forklift truck.

[0015] The storage system preferably comprises a multitude of autonomously moving maintenance vehicles. Furthermore, it can be advantageous if at least one maintenance vehicle has a power supply that can power a transport vehicle picked up by the maintenance vehicle, particularly at the maintenance vehicle's receiving unit. This ensures that the transport vehicle can move autonomously from the receiving unit, for example, onto the guide system or onto a lifting device receiving unit as described below. The power supply preferably comprises a busbar, which is connected, for example, to an energy storage device of the maintenance vehicle.

[0016] Preferably, the passage is assigned to exactly one safety zone and thus to several lifting devices. If, for example, the storage system comprises several safety zones, each passage is assigned to exactly one of the safety zones.

[0017] Furthermore, it is preferably provided that the passage is arranged at a defined position along the boundary and dimensioned such that a maintenance vehicle, together with one or more transport vehicles picked up by the maintenance vehicle receiving unit, can pass through the passage. For example, the passage can be designed as a passageway or as a gate, in particular one that is (permanently) open or automatically opens.

[0018] To allow a person to enter the security zone in a specific area, it is preferably provided that the boundary has a passage, in particular a lockable one, through which a person can enter and / or leave the security zone.

[0019] Particularly preferred is the provision of a release device which is designed to release the passage when all lifting devices and / or all maintenance vehicles are stopped in the safety zone.

[0020] Furthermore, it is advantageous if the unlocking device is in communication with a control system described below and assigned to the safety zone, and is configured to query the control system as to whether the lifting devices and / or the maintenance vehicles in the safety zone are stopped. It is beneficial if the storage system includes a monitoring system configured to monitor the integrity of the safety zone and, as a result of a breach of this integrity, to generate and transmit a stop signal, and a control system assigned to the safety zone, which includes a receiving unit for receiving the stop signal and is configured to stop the lifting devices and / or maintenance vehicles located in the safety zone as a result of the receiving unit receiving the stop signal.This ensures system safety even in the event of a malfunction, for example, if a person is in the safety zone. The receiving unit can be designed as a radio receiver, a wired receiver, or something similar.

[0021] As a rule, the integrity of the safety zone is violated, among other things, when the safety zone is entered by a person, in particular without authorization, without prior notice, with malicious intent or the like, since in this case the lifting devices and, if applicable, maintenance vehicles located in the safety zone pose a danger to the person in question.

[0022] To monitor the integrity of the security zone, for example, passage integrity, crossing the boundary, passing through the passage and / or passing through the passage can be monitored as described below.

[0023] If the boundary includes a passage, it is advantageous for the monitoring system to have a monitoring device associated with the passage, which includes a transmitting unit and is configured to detect a breach of passage integrity and to send a stop signal by means of the transmitting unit as a result of a detected breach of passage integrity. For the purposes of the invention, passage integrity is considered to be breached, in particular, when the passage is traversed, manually unlocked, and / or opened.

[0024] It is advantageous if the monitoring system includes a monitoring device associated with the boundary, which comprises a transmitter unit for sending the stop signal and is configured to detect a crossing of the boundary, particularly by an entity, and to send the stop signal to the receiver unit of the control system via the transmitter unit, especially as a result of a crossing of the boundary. This is particularly useful if the boundary is not physical but optical or virtual, as described below.

[0025] Furthermore, it is advantageous if the monitoring system has a monitoring device associated with the passage, which includes a transmitter unit for sending the stop signal and is configured to detect the passage being passed by an entity and to verify whether the entity passing the passage is a maintenance vehicle, and to send the stop signal to the receiver unit of the control system by means of the transmitter unit, in particular as a result of the passage being passed by an entity other than a maintenance vehicle.

[0026] To verify whether the passing entity is a maintenance vehicle, the passage monitoring device may, for example, include a reader configured to detect and evaluate an identification mark affixed to the maintenance vehicle, such as an RFID tag, QR code, barcode, or similar. For this purpose, it may be stipulated that at least one maintenance vehicle is equipped with an identification mark.

[0027] Alternatively, it can be provided that at least one maintenance vehicle has a transmitter unit for sending a registration signal and the passage monitoring device has a receiver unit for receiving the registration signal. This allows the passage monitoring device to easily verify whether the entity passing through is a maintenance vehicle.

[0028] The transmitting units of the described monitoring devices can be designed, for example, as radio transmitters or as wired transmitters. The stop signal can, in particular, be a data packet transmitted wirelessly or via cable.

[0029] The integrity of the safety zone described above is considered to be violated, in particular, if a violation of the passage integrity, a crossing of the boundary and / or a passage by an entity other than a maintenance vehicle is detected.

[0030] The respective monitoring devices, in particular the monitoring device for passage, boundary, and / or drive-through, may each include a safety light curtain or similar device. To delineate the safety zone, the boundary may comprise a physical boundary, in particular a safety fence, and / or a visual boundary, in particular a boundary line, and / or a virtual boundary.

[0031] The physical boundary can be designed, for example, as a safety fence, cage, wall, curtain, or similar structure. Furthermore, the visual boundary can include, in particular, a boundary line attached to the floor and preferably clearly visible, or a safety light curtain. A virtual boundary can, for example, be stored in a digital map of the storage system. To identify the boundary, it can be displayed, for example, on a screen or with virtual reality glasses. A vibration wristband can also be provided for personnel, which, for example, vibrates when the person wearing the wristband approaches the (virtual) boundary.

[0032] It is advantageous if the lifting device has a vertical support structure and at least one maintenance vehicle is designed to move along the vertical support structure in order to align the maintenance vehicle receiving unit with one of the driving levels. For this purpose, the maintenance vehicle can be designed, in particular, to move horizontally on a floor or driving surface of the storage system to transport the transport vehicle to the maintenance workstation, and also to move vertically along the vertical support structure. The maintenance vehicle can be designed as described, for example, in WO 2018 / 189110, WO 2017 / 064401, WO 2019 / 072432, WO 2021 / 104921 and / or WO 2021 / 104922.

[0033] Preferably, in the method for operating the storage system, the transport vehicle is transferred in step ii) by moving the maintenance vehicle along the vertical support structure to the respective driving level and aligning the maintenance vehicle receiving unit on the respective driving level, transferring the "maintenance-requiring" transport vehicle from the guidance system to the maintenance vehicle receiving unit, and then moving the maintenance vehicle along the vertical support structure together with the "maintenance-requiring" transport vehicle to the transfer level.

[0034] Furthermore, it is advantageous if the lifting device has a vertical support structure and a lifting device receiving unit mounted vertically on the vertical support structure via a lifting drive for receiving at least one transport vehicle. Advantageously, in step ii) of the method for operating the storage system, it is provided that the transport vehicle is transferred by aligning the lifting device receiving unit at the respective travel level using the lifting drive, transferring the "maintenance-requiring" transport vehicle from the guidance system to the lifting device receiving unit, aligning the lifting device receiving unit together with the "maintenance-requiring" transport vehicle at the transfer level, and transferring the "maintenance-requiring" transport vehicle from the lifting device receiving unit to the maintenance vehicle receiving unit.

[0035] To increase the availability of the lifting device and / or to decouple the lifting device from the maintenance vehicles, it is preferably provided that a buffer system is provided on the lifting device for taking over at least one transport vehicle from the lifting device and transferring the at least one transport vehicle to a maintenance vehicle and / or for taking over at least one transport vehicle from a maintenance vehicle and transferring the at least one transport vehicle to the lifting device.

[0036] It is advantageous if the lifting device receiving unit and the maintenance vehicle receiving unit comprise coupling elements that can be engaged with each other, by means of which the at least one maintenance vehicle can be positioned relative to the lifting device receiving unit and preferably locked in a docking position. This ensures a reliable transfer of transport vehicles between the lifting device receiving unit and the maintenance vehicle receiving unit.

[0037] Furthermore, it is advantageous if the lifting device has a power supply that can power a transport vehicle picked up by the lifting device, particularly at the lifting device's receiving unit. This ensures, for example, that the transport vehicle can automatically move from the lifting device's receiving unit, for instance, onto the guidance system or onto the maintenance vehicle receiving unit of a maintenance vehicle positioned at the lifting device. The power supply preferably comprises a busbar, which is connected, for example, to the power grid.

[0038] The guidance system of the racking units can be arranged on all travel levels and, for example, include at least one guide rail per travel level. It is advantageous if the lifting device receiving unit and / or the maintenance vehicle receiving unit each include guide rails arranged in pairs for the at least one transport vehicle.

[0039] To exchange transport vehicles efficiently and easily, it can be provided that the lifting device receiving unit and / or the maintenance vehicle receiving unit each have a first receiving unit and a second receiving unit arranged above the first receiving unit for receiving one transport vehicle each, which preferably each include guide rails arranged in pairs for the at least one transport vehicle.

[0040] It is advantageous that the guidance system in the driving levels includes guide rails arranged in pairs for at least one transport vehicle or for several transport vehicles.

[0041] The method for operating the storage system advantageously provides that in step i) a replacement transport vehicle is provided at the maintenance vehicle receiving unit by the autonomously moving maintenance vehicle, which in step ii) is handed over to the guidance system in the respective driving level after the "maintenance-required" transport vehicle has been taken over from the respective driving level.

[0042] For this purpose, it may be provided that the storage system has one or more (additional) transport vehicles, in particular of the same design, which can be used as replacement transport vehicles.

[0043] An exchange of the "maintenance-requiring" transport vehicle for a replacement transport vehicle can take place, for example, at the transfer level, whereby the replacement transport vehicle is taken over by the lifting device receiving unit and the "maintenance-requiring" transport vehicle is handed over to the maintenance vehicle receiving unit. Similarly, the exchange of the "maintenance-requiring" transport vehicle for a replacement transport vehicle can take place at the driving level, whereby the "maintenance-requiring" transport vehicle is taken over by the lifting device receiving unit or by the maintenance vehicle receiving unit and the replacement transport vehicle is handed over to the guidance system at the respective driving level.For the exchange process, it is particularly advantageous that the lifting device receiving unit and / or the maintenance vehicle receiving unit, as described above, each have a first receiving unit and a second receiving unit arranged above the first receiving unit for receiving one transport vehicle each. In this way, one receiving unit can be used for the transport vehicle requiring maintenance and the other receiving unit for the replacement transport vehicle.

[0044] To further increase plant availability, it may be possible to design the rack aisle units according to one of the aspects described below.

[0045] Furthermore, it may be provided that one of the transport vehicles is classified as "requiring maintenance" by the control unit, in particular according to a method according to one of claims 45 to 54, if the analysis parameter or at least one of the analysis parameters deviates from the respective analysis parameter-specific target value range.

[0046] It is particularly preferred that a transport vehicle be made available at the maintenance site only if it has been classified as requiring maintenance.

[0047] The transport vehicle can be classified as requiring maintenance in the context of event-driven maintenance following a prior evaluation of an analysis parameter by an evaluation system, as described below, and / or in the context of scheduled maintenance following the expiration of a defined time interval. The defined time interval is based, for example, on a predetermined maintenance schedule for the transport vehicle.

[0048] The task is further solved by a racking unit of the type mentioned above, wherein a recording system for recording at least one analysis parameter of the at least one transport vehicle is provided, which is connected to an evaluation system for comparing the at least one analysis parameter with at least one analysis parameter-specific target value range, wherein the evaluation system is set up to classify the transport vehicle as requiring maintenance if the at least one analysis parameter deviates from the at least one respective target value range.

[0049] In a preferred embodiment, the storage system comprises at least one racking unit, which includes an automated transport vehicle. The transport vehicle is equipped with a data acquisition system for recording operating parameters and an evaluation system for automatically determining maintenance requirements. The evaluation system is configured to compare at least one recorded analysis parameter with an associated target value range and to classify the transport vehicle as requiring maintenance if the analysis parameter lies outside the target value range. The racking unit is functionally integrated into the storage system, so that maintenance diagnostics are performed as an integral part of the automated operating process. This allows maintenance to be carried out automatically and on an as-needed basis, thereby increasing the availability of the storage system.

[0050] Furthermore, the task is solved by a procedure for determining the maintenance requirements of a transport vehicle of the type mentioned above, wherein at least one analysis parameter of the transport vehicle is recorded by means of the recording system and transmitted to the evaluation system, the recorded analysis parameter is compared by the evaluation system with the analysis parameter-specific target value range and the transport vehicle is classified as requiring maintenance if the analysis parameter deviates from the respective target value range.

[0051] A particular advantage of the invention is that the analysis parameter can be checked automatically, especially by the transport vehicle itself, and maintenance can therefore be carried out on an as-needed basis. Thus, fixed maintenance intervals are not required, which increases the availability of such a racking unit and, furthermore, of a storage system with such a racking unit.

[0052] It is advantageous if the racking unit, in particular of the storage system described above, has a large number of superimposed driving levels, for example one driving level per racking level.

[0053] The acquisition system is particularly well-suited for recording multiple analysis parameters. For each analysis parameter, one or more parameter-specific target value ranges are provided, against which the respective analysis parameter is compared.

[0054] The setpoint range can extend from a lower limit to an upper limit or threshold. The lower and upper limits can optionally be identical, so that the setpoint range comprises only a single value and thus essentially corresponds to a single setpoint. Alternatively, the setpoint can also be open-ended downwards, so that an upper limit of the setpoint range corresponds to an upper threshold. Likewise, the setpoint range can be open-ended upwards, so that a lower limit of the setpoint range corresponds to a lower threshold. For the purposes of the invention, a "deviation from the setpoint range" is to be understood as meaning that the value recorded for the respective analysis parameter lies outside the setpoint range, in particular being greater than the upper limit or less than the lower limit.

[0055] Furthermore, multiple, mutually spaced setpoint ranges can be provided for an analysis parameter. For example, if the analysis parameter is a frequency, a first setpoint range can be defined for a fundamental frequency, and subsequent setpoint ranges can each be defined for a permissible resonant frequency.

[0056] The data collection system can, for example, be centralized, particularly stationary, and include a central data collection unit that is connected to the system via data technology. Alternatively, the data collection system can be decentralized and / or mobile, with one or more decentralized data collection units.

[0057] It is particularly preferred that at least one transport vehicle has a recording unit of the recording system arranged on it.

[0058] Just like the recording system, the evaluation system can also be centrally designed and have a central output unit connected to the recording system in terms of data technology, or one or more decentralized output units connected to the recording system in terms of data technology, in particular arranged on at least one transport vehicle.

[0059] It is therefore advantageous if at least one transport vehicle has an evaluation unit of the evaluation system mounted on it.

[0060] The at least one analysis parameter preferably comprises different parameters, each relating to different components of the transport vehicle, such as a drive system comprising the drive mechanism, the wheels, and optionally drive shafts. Advantageously, the at least one analysis parameter includes at least one drive mechanism analysis parameter and / or at least one wheel analysis parameter, which are preferably acquired by means of the acquisition system.

[0061] At least one drive analysis parameter can be selected from the group: drive revolutions (per unit of time or until the drive is blocked), drive motor current (per unit of time or until the drive is blocked), drive belt tension, rotation of a drive shaft of the transport vehicle, and the like.

[0062] Furthermore, at least one wheel analysis parameter can be selected from the group: wheel revolutions per unit distance, wheel bearing vibrations, and the like.

[0063] Wear on the wheels and / or pickup material (material accumulating on the wheels) can affect the wheel diameter and therefore the wheel circumference. Wear reduces the wheel diameter, while pickup material increases it. Due to this change in wheel circumference, a different number of wheel rotations are required to cover the same distance compared to before the wear and / or pickup occurred.

[0064] To verify this, it may be possible, for example, to move the transport vehicle along a unit distance along the aisle by means of the drive system, recording the number of wheel revolutions achieved in order to determine the number of wheel revolutions per unit distance, after which the recorded number of revolutions is compared by the control unit with a target value range for the number of revolutions.

[0065] Similarly, wear and / or a pickup can affect vibration of the wheels and / or the wheel bearings, which can be measured and compared with a target value range for the corresponding vibration.

[0066] It is advantageous if the transport vehicle has drive shafts coupled to the drive system, on which wheels are mounted, and if the drive system can be switched either to a driving mode in which the drive shafts are driven in the same direction of rotation, or to an analysis mode in which the drive shafts, especially in pairs, are driven in different directions of rotation.

[0067] For example, to check for play in a drive train of the drive system, it may be provided that the drive system of the transport vehicle is switched to analysis mode, whereby any rotation of the drive shafts achieved in this mode is recorded and compared by the control unit with a target value range for the rotation of the drive shafts.

[0068] The rotation of the drive shafts can be measured, for example, by the angle of rotation achieved or the corresponding number of revolutions. For instance, an angle of rotation of 180°, 360°, 540°, and so on, can be achieved, which in turn corresponds to a number of revolutions of * , 1 , 1 *, and so forth. Increased rotation of the drive shafts can, for example, indicate excessive play in the drivetrain of the vehicle, which necessitates maintenance of the transport vehicle.

[0069] If the drive shafts are driven in opposite directions, the transport vehicle remains in its position. Depending on the play in the drivetrain, the drive shafts can rotate further or less. The play in the drivetrain can therefore be checked by observing the rotation of the drive shafts.

[0070] It is advantageous if the drive system has a separate drive for each drive shaft.

[0071] Optionally, in addition to or as an alternative to the described analysis mode, it may be provided that the transport vehicle can be switched to a (further) analysis mode in which only a single drive shaft is driven.

[0072] To transfer individual items between the transport vehicle and the storage rack, the transport device can be extended using the extension drive (relative to the rack aisle in both directions, i.e., into the left and right storage racks). For this purpose, the transport device can have one or more extendable item handling elements, such as an extendable platform, two parallel telescopic arms, or similar components. If multiple item handling elements are provided, the extension drive can be coupled to both of them to extend them synchronously, or the drive can have a separate drive for each item handling element to extend them synchronously or individually.

[0073] Advantageously, it is provided that at least one analysis parameter includes at least one extension analysis parameter, selected from the group consisting of the holding force acting on the transport device during extension, the motor current of the extension drive, and the motor revolution count of the extension drive until the extension drive is blocked.

[0074] It is advantageous if, in the procedure for determining the maintenance requirements of the transport vehicle, at least one driving analysis parameter is recorded using the data acquisition system.

[0075] Furthermore, it is advantageous if the transport device has at least one transport element, pivotable on the transport device by means of a swivel drive, for the positive-locking transport of the unit load. Preferably, the transport device comprises several transport elements, each of which is assigned a swivel drive unit of the swivel drive. The transport elements can, for example, be pivotably mounted on the unit load transfer means. Such a transport device is known, for example, from WO 2016 / 168878 Al.

[0076] It is advantageous if at least one analysis parameter has at least one swivel analysis parameter, selected from the group motor current of the swivel drive, motor revolution speed of the swivel drive up to a blockage of the swivel drive and swivel angle of the transport elements.

[0077] Furthermore, it may be provided that a test system for physical interaction, in particular for mechanical, electrical and / or optical interaction, is provided with the transport vehicle, wherein the test system is assigned to at least one of the driving levels.

[0078] It is advantageous if the test system has one or more detection units of the detection system, each of which is assigned to a driving level.

[0079] To enable mechanical interaction with the transport vehicle, the test system may be designed to include a blocking device. This blocking device can be arranged, for example, in the storage rack and / or aisle and be designed as a disruptive structure or matrix against which the transport vehicle and / or transport device can be positioned.

[0080] The interaction – such as a bump or scrape – can cause an increased restraint force, which is detected by the monitoring system and serves as an analysis parameter. The restraint force can be indirectly determined via the motor current of the relevant drive and compared to a stored target value range by an evaluation unit. A deviation may indicate that the transport vehicle requires maintenance. The blocking device can thus support an automated, objective diagnosis regarding maintenance needs.

[0081] Optionally, the mechanical interaction generated by the blocking device can be incorporated into an automated maintenance diagnostic procedure. In this procedure, analysis parameters—such as a holding force—are recorded by a sensor system and compared to a predefined target value range by an evaluation system. A deviation can lead to the automated classification of the transport vehicle as requiring maintenance.

[0082] It is advantageous if the test system includes a blocking device to prevent the pivoting movement of at least one transport element. This allows the transport element to be blocked at a specific angle, the pivoting angle to be measured, and thus the pivoting drive to be tested.

[0083] It is therefore advantageous if at least one transport element is aligned with the blocking device to block the swivel movement and swiveled out until the swivel movement is blocked by the blocking device, in particular mechanically limited. In this process, at least one swivel analysis parameter, for example, the swivel angle of the at least one transport element, is recorded and compared with a target value for that parameter. A deviation from the target value range can indicate that the swivel drive requires maintenance and can be used for the automated classification of the transport vehicle as requiring maintenance.

[0084] To measure the swivel angle, for example, the swivel drive can include a rotary encoder. It is advantageous if the test system has a blocking device to prevent movement of the transport device along an extension direction. For this purpose, the blocking device can, for example, include an obstruction, particularly a die, which has one or more recesses into which the transport device can be inserted. If the transport device collides with or grazes the obstruction during extension, this results, for example, in an increased restraint force. The restraint force can be evaluated, for example, based on the motor current of the drive.

[0085] It is advantageous if the transport device is extended by the extension drive in the direction of the locking device, whereby at least one extension drive parameter, in particular the holding force and / or the motor current of the extension drive, is recorded and compared with a target value range for the at least one extension drive parameter. A deviation from the target value range can indicate that the transport device requires maintenance and can be used for the automated classification of the transport vehicle as requiring maintenance.

[0086] Advantageously, the test system includes a blocking device to prevent the transport vehicle from moving along the longitudinal direction of the storage rack. For example, a rack upright can serve as the blocking device, against which the transport vehicle is positioned with the transport device. Alternatively, a stop element can be placed in the transport vehicle's travel path, particularly in the rack aisle, or positioned at an end of the travel path, particularly the rack aisle, so that the transport vehicle can be positioned against the stop element.

[0087] It is advantageous if the transport vehicle is driven by the drive system and moved in the direction of the blocking device to block the driving movement until the driving movement is blocked by the blocking device, whereby a drive system parameter, in particular a motor current of the drive system or a toothed belt tension, is detected and compared with a setpoint range for the drive system parameter.

[0088] It is advantageous if the receiving width for a unit item on the transport device is adjustable by means of a width adjustment device, and if at least one analysis parameter includes a set receiving width. Preferably, the transport device comprises a receiving platform which has a receiving width and on which at least one unit item can be positioned, and / or unit item transfer means which are arranged parallel to each other and spaced apart by a receiving width, such that at least one unit item can be positioned between the unit item transfer means, and a width adjustment device by which the receiving width for the at least one unit item can be adjusted (changed), wherein the at least one analysis parameter includes a set receiving width.

[0089] For this purpose, the receiving platform can, for example, have a width-adjustable receiving base, and / or load supports that can be moved towards each other, and / or the transport device can have load transfer devices that can be moved towards each other.

[0090] Furthermore, it is advantageous if the test system includes a locking device for blocking the width adjustment of the transport device. In particular, the test system may include a locking device for blocking the width adjustment on the receiving platform and / or on the unit load transfer devices.

[0091] The blocking device for blocking the movement of the transport device along an extension direction, for blocking the pivoting movement and / or the blocking device for blocking the width adjustment can in particular be formed by the same blocking device, for example by the same disruptive structure or die.

[0092] Alternatively, the test system can include a reference item, such as a box or block, against which the transport device is positioned. If the transport device includes the item transfer elements, these are positioned against the reference item on opposite sides. The resulting intake width can be recorded and compared with a target range for the intake width. This target range specifically includes the width of the reference item. A deviation from the target range may indicate incorrect adjustment or mechanical wear and be classified as requiring maintenance.

[0093] To detect and, if necessary, identify individual items and / or free storage spaces in a shelf compartment of the storage rack, at least one transport vehicle, or several transport vehicles, may each be equipped with sensors for detecting markings in the storage rack and a data processing unit for evaluating the detected markings. At least one of the analysis parameters may include a detectability value, which indicates the degree to which the detected reference marking is recognized. In this case, the sensors can be automatically classified as requiring maintenance, with the detectability value serving as the analysis parameter.

[0094] The measure of whether the detected reference mark has been recognized, i.e., the detectability value, can be binary and simply indicate whether the reference mark was detected or not. The target value range could be, for example, "detection successful," "0," or "1." Similarly, the detectability value can also be expressed as a percentage or proportion, indicating the number of successful detections of the reference mark, particularly relative to the number of attempts performed.

[0095] To enable optical interaction with the transport vehicle, the test system can be provided with one or more reference markings that are optically detectable by the transport vehicle. The reference marking can be, for example, a barcode, QR code, number, pattern, or the like. It is particularly preferred that several driving levels, and especially each driving level, are assigned a reference marking. The reference marking(s) can be arranged, in particular, in the shelf areas of the storage racks.

[0096] It is therefore advantageous if the reference marking is detected by means of the sensors for detecting markings and evaluated by the evaluation system, whereby the detectability value is determined and compared with a target value range for the detectability value.

[0097] To supply energy to at least one transport vehicle or several transport vehicles, the racking unit and / or the racking units of the storage system described above can each include an energy supply.

[0098] Furthermore, the storage aisle unit and / or units of the storage system described above preferably include an energy storage device, preferably rechargeable, located on the transport vehicle. At least one analysis parameter may, in particular, include the capacity of the energy storage device.

[0099] Advantageously, the power supply for each transport level comprises a conductor rail arranged on the storage rack and a current collector arranged on at least one transport vehicle for electrical contact with the respective conductor rail. The conductor rails are expediently connected to a power grid. Preferably, the current collector includes several sliding contacts.

[0100] It is particularly preferred that the pantograph has a warning contact and that at least one analysis parameter includes a contact value of the warning contact by the busbar. In particular, the sliding contacts of the pantograph each have a warning contact and that at least one analysis parameter includes a contact value of the respective warning contact by the busbar.

[0101] Advantageously, the contact value is recorded by the acquisition system and compared by the evaluation system with a target value range for the contact value.

[0102] The sliding contacts and the warning contact each include a contact surface for contacting the busbar, with the contact surface of the warning contact being recessed relative to the contact surface of the respective sliding contact. Under normal operating conditions, the warning contact therefore does not make contact with the busbar when the sliding contacts do. As the sliding contacts wear, the distance between the contact surfaces of the respective sliding contact and the warning contact decreases until the warning contact also makes contact with the busbar. This indicates excessive wear of the sliding contact and therefore a need for maintenance of the transport vehicle.

[0103] The contact value of the contactor can, for example, be binary and simply indicate whether or not an electrical contact has been established between the busbar and the contactor. The target value range can be, for example, "Contact established," "0," or "1." Similarly, the detectability value can include, for example, a percentage or proportion indicating the number of contacts, particularly per unit of time. It is advantageous that data transmission between a higher-level control system, especially the racking unit or the storage system, and the transport vehicle occurs via the power supply, specifically the sliding contact(s), and / or via a wireless connection, such as WLAN and / or radio, and that at least one analysis parameter pertains to the quality of the data transmission.

[0104] It is advantageous to record the parameter concerning the quality of data transmission using the acquisition system and to compare it with a target value range for the quality of data transmission using the evaluation system.

[0105] The parameter concerning the quality of data transmission can, for example, include the number of connection drops per unit of time or the number of faulty data packets per unit of time. A particularly high, specific, or threshold-high number of faulty data packets or connection drops can therefore indicate a faulty electrical contact of the sliding contact or a degraded communication link.

[0106] The at least one transport vehicle is preferably a single-level storage and retrieval machine (shuttle). Preferably, one transport vehicle is arranged on each travel level, with the number of travel levels corresponding to the number of rack levels. However, fewer transport vehicles than travel levels can also be provided, with transport vehicles being moved between the travel levels by means of the lifting device in order to serve all travel levels.

[0107] The at least one transport vehicle can also be a multi-level storage and retrieval machine. Preferably, one transport vehicle is arranged on each travel level, with fewer travel levels than storage levels. A multi-level storage and retrieval machine can serve several storage levels on one of the travel levels. Alternatively, fewer transport vehicles than travel levels can be provided, with transport vehicles being moved between the travel levels by means of the lifting device.

[0108] Optionally, at least one transport vehicle can have a rechargeable energy storage unit, and the racking unit can have at least one charging station for the energy storage unit, to which the at least one transport vehicle can dock. It is advantageous if the racking unit and / or racking units of the previously described storage system have a large number of identical transport vehicles.

[0109] To better understand the invention, it is explained in more detail with reference to the following figures.

[0110] They show, in highly simplified, schematic representations:

[0111] Fig. 1 shows a bearing system in top view;

[0112] Fig. 2 shows a first shelf aisle unit in side view;

[0113] Fig. 3 shows a second shelf aisle unit in side view;

[0114] Fig. 4 shows a third shelf aisle unit in side view;

[0115] Fig. 5 shows a transport vehicle in perspective view;

[0116] Fig. 6 shows a section of a storage rack with a transport vehicle; and

[0117] Figs. 7a to 7d show a test system for the physical interaction with the transport vehicle.

[0118] It should be noted at the outset that in the differently described embodiments, identical parts are provided with the same reference numerals or component designations, and the disclosures contained in the entire description can be applied analogously to identical parts with the same reference numerals or component designations. Furthermore, the positional designations chosen in the description, such as top, bottom, side, etc., refer to the figure directly described and illustrated and must be applied analogously to the new position if the position changes.

[0119] Fig. 1 shows a schematic top view of a storage system 1, which has several adjacent aisle units 2. Each aisle unit 2 comprises two parallel storage racks 3 with an intermediate aisle 4. A guide system 5 for transport vehicles 7 is provided in each of the aisles 4, which, as shown in Fig. 1, has, for example, guide rails 6 arranged in pairs. Unit goods S can be stored in the storage racks 3, particularly in stacked compartments of the storage racks 3, as indicated by some exemplary unit goods S shown in Fig. 1. The unit goods S can be stored and / or retrieved by the transport vehicles 7. The unit goods S are, for example, pallets, containers, cartons, hanging garments, in particular hanging bags or garments on hangers, so-called "Garment On Hangers (GOH)," or the like.

[0120] At one end of the rack aisle units 2, each includes a lifting device 8 for vertically transferring transport vehicles 7 between superimposed driving levels FE and a transfer level UE, as shown in Fig. 2.

[0121] Furthermore, the storage system 1 comprises several maintenance vehicles 9, which are designed to transport transport vehicles 7 between the lifting devices 8 and a maintenance workstation (WAP). For this purpose, each maintenance vehicle 9 includes a maintenance vehicle receiving unit 10, which, as schematically shown in Fig. 1, can include guide rails 6.

[0122] The multiple rack aisle units 2 are surrounded by a safety zone SZ, which is bounded by a barrier 11. The maintenance workstation WAP is located outside the safety zone SZ and is preferably accessible to persons for carrying out maintenance work on a transport vehicle 7 provided at the maintenance workstation WAP.

[0123] To allow maintenance vehicles 9 to cross the boundary 11, the boundary 11 is provided to have a passage 12. Furthermore, an optional passage 13, shown as a dashed line in Fig. 1, may be provided, which allows a person to enter the safety zone SZ.

[0124] To detect a breach of the integrity of the security zone SZ, in particular unauthorized entry by a person, the storage system 1 can include an optional monitoring system 14, shown in dashed lines in Fig. 1, which, for example, has a monitoring device for the boundary 11, the passage 12, and / or the passage 13. Furthermore, an optional buffer system 15 can be provided for transferring a transport vehicle 7 from the lifting device 8, as shown in dashed lines in Fig. 1 by way of example for one of the rack aisles 4. The transport vehicle 7 can thus be transferred from the lifting device 8 into the buffer system 15 and from the buffer system 15 to the maintenance vehicle 9.

[0125] Figures 2 to 4 show a schematic side view of a section of a racking unit 2. It can be seen that the storage rack 3 has a plurality of storage compartments arranged in stacked racking levels RE. Furthermore, several driving levels FE are provided, and a transport vehicle 7 can be arranged, for example, on some or all of the driving levels FE.

[0126] The lifting device 8 can have a vertical support structure 16. A lifting device receiving unit 18, which can be moved vertically by means of a lifting drive 17, can be arranged on the vertical support structure 16, as shown in Fig. 2 and Fig. 3. Analogous to the guide system 5 and the maintenance vehicle receiving unit 10, the lifting device receiving unit 18 can also comprise guide rails 6 arranged in pairs.

[0127] As shown in Fig. 3, the maintenance vehicle receiving unit 10 and / or the lifting device receiving unit 18 can optionally each comprise a first receiving unit 19a and a second receiving unit 19b, so that two transport vehicles 7 can be received one above the other.

[0128] For the transfer of a transport vehicle 7 between the maintenance vehicle receiving unit 10 and the lifting device receiving unit 18, the lifting device receiving unit 18 can be aligned with the maintenance vehicle receiving unit 10 in the transfer plane UE, as shown in Figs. 2 and 3. Thus, for example, a transport vehicle 7 requiring maintenance can be transferred from the lifting device receiving unit 18 to the maintenance vehicle receiving unit 10, as shown in Fig. 2, and / or, as shown in Fig. 3, a replacement transport vehicle 7' can be transferred from the maintenance vehicle receiving unit 10 to the lifting device receiving unit 18. As can be seen in Fig. 3, the first and second receiving units 19a, 19b are aligned with each other if necessary. To remove a transport vehicle 7 requiring maintenance from the respective driving plane FE, the lifting device receiving unit 18 can be aligned with the maintenance vehicle receiving unit 10, as shown in Fig. 2.2 shown as dashed lines, are aligned to the respective driving plane FE.

[0129] In order to deliver a replacement transport vehicle 7' to the respective driving level FE, the lifting device receiving unit 18, as shown in dashed lines in Fig. 3, can be aligned, for example, with the second receiving unit 19b on the respective driving level FE, after the transport vehicle 7 to be serviced has been taken from the respective driving level FE.

[0130] Alternatively, the maintenance vehicle 9 can be configured to travel along the vertical support structure 16, as shown in Fig. 4. In this embodiment, a lifting device, as described in the preceding embodiments according to Figs. 2 and 3, can be omitted. The maintenance vehicle receiving unit 10 can also optionally include a first and second receiving unit 19b in this embodiment, for example, to provide a replacement transport vehicle 7', as shown in the dashed lines. To pick up a transport vehicle 7 requiring maintenance from the respective travel level FE and / or to deliver a replacement transport vehicle 7' to it, the maintenance vehicle receiving unit 10 can be aligned with the respective travel level FE, as previously described for the lifting device receiving unit 18.

[0131] To operate the storage system 1 shown in the illustration, a maintenance vehicle 9 can be provided at the lifting device 8 in a first step, as illustrated by way of example in Figs. 2 to 4. Optionally, a replacement transport vehicle 7' can be provided, as shown in Fig. 3 and depicted in dashed lines in Fig. 4.

[0132] In step ii), a transport vehicle 7 requiring maintenance can be removed from its driving level FE. This can be done, for example, as described above and as shown in dashed lines in Figs. 2 and 3, by the lifting device receiving unit 18 or by the maintenance vehicle receiving unit 10, as shown in Fig. 4. If necessary, the previously provided replacement transport vehicle 7' can then be placed into the respective driving level FE.

[0133] In step ii), the transport vehicle 7 requiring maintenance is moved downwards to the transfer level UE, where it may be transferred to the maintenance vehicle 9 and transported by the maintenance vehicle 9 in step iii), as shown schematically in Fig. 1. At the maintenance workstation WAP, the maintenance of the transport vehicle 7 can now be carried out by a person or automatically by a maintenance robot.

[0134] Figures 5 and 6 show an exemplary transport vehicle 7 designed as a single-level storage and retrieval machine in a perspective view, as well as a close-up of a section of a storage rack 3 and a transport vehicle 7.

[0135] The transport vehicle 7, for example, has a base frame 20, several wheels 21 rotatably mounted on the base frame 20, a drive unit 22 for driving at least one wheel 21, sensors 23 (shown in Fig. 7a, Fig. 7b and Fig. 7c) for detecting markings arranged in the storage rack 3, a control unit 36 ​​and / or control electronics for controlling the drive unit 22. Optionally, the transport vehicle 7 may have an energy storage device (not shown).

[0136] To couple the drive unit 22 with at least one wheel 21, the transport vehicle 7 can have one or more drive shafts 40. Two wheels 21 are mounted on each drive shaft 40. The drive shafts 40 are each supported on the base frame 20 by bearing devices, as not shown in detail. The drive shafts 40 can be coupled via a traction element of a traction drive, not shown, so that all wheels 21 are driven. The traction element is, for example, formed by a toothed belt.

[0137] Furthermore, the transport vehicle 7 includes a transport device 24 that can be extended by means of an extension drive 25, by means of which unit loads S can be transferred between the storage rack 3 and the transport vehicle 7. In the illustrated example, the transport device 24 has a receiving platform, which preferably includes two unit load supports 26. In addition, the transport device 24 preferably includes two parallel and preferably synchronously extendable unit load transfer means 27, which can, for example, be designed essentially as extendable telescopic arms. However, according to one possible embodiment, the unit load transfer means 27 can each be extended independently of one another by means of an extension drive 25 assigned to each unit load transfer means 27.As can be seen here, a receiving width AB on the receiving platform, on which at least one piece of goods S can be positioned, and / or a receiving width AB between the parallel piece goods transfer means 27 can be set by means of a width adjustment device 28.

[0138] The receiving width AB can, for example, correspond to a horizontal distance between the unit load supports 26 and / or a horizontal distance between the unit load handling devices 27.

[0139] The receiving width can be adjusted in particular by means of the width adjustment device 28, for example by moving the load supports 26 and / or the load transfer means 27 towards each other.

[0140] Furthermore, it is preferably provided that the transport device 24 has several transport elements 29. The transport elements 29 are preferably mounted on the unit load transfer means 27 and / or can be pivoted independently of one another between an actuating position and a starting position by means of a pivoting drive. In the starting position, the transport elements 29 are pivoted inwards, and in the actuating position, the transport elements 29 enclose a pivot angle of more than 0°, preferably more than 30°, with the transport device 24, in particular with the respective unit load transfer means 27, as shown in Fig. 5 for the transport elements 29 at the front and rear in the direction of extension. Optionally, (not shown) middle transport elements 29 can also be provided.

[0141] As can be seen in Fig. 6, the wheels 21 of the transport vehicle 7 rest on the guide rails 6 of the previously described guide system 5 of the racking unit 2. Furthermore, it can be provided that the transport vehicles 7 are supplied with power and / or data via a conductor rail arrangement. For this purpose, a conductor rail 30 can be arranged on the storage rack 3 and a current collector 31 on the transport vehicle 7. The current collector 31 can comprise one or more sliding contacts.

[0142] Optionally, the sliding contact can be equipped with a warning contact 32, which is only contacted by the busbar 30 when a certain amount of material has worn away from the sliding contact. Contacting the warning contact 32 can therefore indicate wear of the sliding contact. For example, the contact value of the warning contact 32 can be recorded by the detection system described below to monitor wear of the sliding contact. Alternatively, the quality of the data transmission can be monitored, for example, the number of faulty data packets per unit of time, whereby a high number of faulty data packets per unit of time also indicates a power supply requiring maintenance.

[0143] To determine whether a transport vehicle 7 requires maintenance, it can be provided that one or more analysis parameters relating to the transport vehicle 7 are recorded by a data acquisition system and evaluated by an evaluation system. During evaluation, the recorded analysis parameter is compared with a target value range specific to that parameter. For the purposes of the invention, a transport vehicle 7 is considered to require maintenance if at least one of the recorded analysis parameters deviates from the respective target value range.

[0144] The analysis parameters can include a parameter relating to the drive system 22 (drive system analysis parameter), a parameter relating to the wheels 21 (wheel analysis parameter), a parameter relating to the extension of the transport device 24 (extension analysis parameter), a parameter relating to the swiveling of the transport elements 29 (swivel analysis parameter), a parameter relating to a set receiving width of the transport device 24, a parameter relating to the detectability of a reference mark 35 by the sensor system 23 (detectability value), a parameter relating to the capacity of the energy storage device, a parameter relating to the wear of the sliding contacts of the transport vehicle 7 (for example, contact value of the warning contact) and / or a parameter relating to the quality of a data transmission between the transport vehicle 7 and a higher-level control system 39 (shown exclusively in Fig. 2).

[0145] To record at least one of the analysis parameters, the transport vehicle 7 can have a recording unit 37 of the recording system. To evaluate the recorded analysis parameters, the transport vehicle 7 can also include a data processing unit 38 of the evaluation system. The recording unit 37 and / or the data processing unit 38 can each be independent components or subunits of the aforementioned control unit 36. For example, to determine the wear of the wheels 21, the transport vehicle 7 can be moved along a unit path, for example, from one shelf upright to the next. In this process, the recording unit 37 can record the number of revolutions of the wheels 21.If the number of revolutions deviates from the expected number of revolutions of the running wheels 21 required for the unit distance, this indicates wear of the running wheels 21, which is why the transport vehicle 7 can be classified as "in need of maintenance" in this case.

[0146] Furthermore, the drive unit 22 can be selectively switched between a driving mode and an analysis mode, particularly by means of the control unit 36. In driving mode, the drive shafts 40 rotate in the same direction. When switching to analysis mode, the drive shafts 40 rotate in opposite directions, so that no net movement of the transport vehicle 7 results. In this mode, for example, the rotation of the drive shafts 40, in particular the angle of rotation up to their standstill, can be detected. If the angle of rotation or the rotation deviates from an expected target value or target value range, this indicates, for example, excessive play in the drive unit 22, which is why the transport vehicle 7 can be classified as requiring maintenance in this case.

[0147] To further check the maintenance requirements of the transport vehicle 7, the rack aisle 4 or rack aisles 4 of the storage system 1 can be designed as described in connection with Figs. 7a to 7c.

[0148] Figures 7a and 7b show a section of a racking unit 2 with a test system arranged in the storage rack 3 for physical interaction with the transport vehicle 7. The physical interaction can, in particular, include mechanical, optical, electrical, and / or magnetic interaction. The test system can be assigned to at least one driving level FE. Preferably, the racking unit 2 comprises several identical test systems, each assigned to a driving level FE.

[0149] For mechanical interaction, the test system preferably has one or more blocking devices. A (first) blocking device of the test system can be configured to allow the extension movement of the transport device 24, in particular the unit load transfer means 27, only in certain areas and to block or impede it in other areas. For this purpose, the (first) blocking device can have a (hatched) obstruction structure 33 with clearances into which the transport device 24, in particular its unit load transfer means 27, can be inserted, as shown in Fig. 7a.

[0150] For example, if the transport device 24 is misaligned or has an incorrectly set receiving width AB, the transport device 24, particularly its load transfer means 27, can collide with or rub against the obstruction 33 during extension, as shown in Fig. 7b, thereby increasing the restraining force acting on the transport device 24. In the illustrated embodiment, the obstruction 33 prevents the left load transfer means 27 from extending completely. If the load transfer means 27 are driven by a single extension drive 25, the right load transfer means 27 will also be prevented from extending completely. If each load transfer means 27 is driven by an independent extension drive 25, the right load transfer means 27 can extend completely, although this is not shown.

[0151] To check the analysis parameter relating to the extension drive 25, the transport device 24, in particular its unit load transfer means 27, can be extended in the extension direction and moved into the clearances of the blocking device or obstruction structure 33. The restraining force can then be recorded using the detection system, for example by measuring the motor current of the extension drive 25. In the case of an increased restraining force, as shown in Fig. 7b, maintenance of the transport vehicle 7 with regard to the transport device 24 may be required.

[0152] Furthermore, a (second) blocking device of the test system can be configured to block the movement of the transport vehicle 7 along the storage racks 3. For this purpose, the transport vehicle 7, in particular with the transport device 24, can be positioned against the (second) blocking device. The previously described obstruction 33, a rack upright 41, or the like can also serve as a blocking device for the movement, against which the transport device 24, in particular its unit load transfer means 27, can be positioned. A (further / third) blocking device of the test system can also include a stop element 34, shown hatched in Fig. 7c, against which the transport elements 29 can be positioned to check a pivoting movement. The stop element 34 can also be formed by the previously described obstruction 33.

[0153] The transport elements 29 can be swung out and a swivel angle a can be recorded by the detection system. The swivel angle a can then be compared with a target value range. If the actual swivel angle a deviates from the target value range, maintenance is required with regard to the swivel drive 42.

[0154] Furthermore, the locking device can be used to block the width adjustment of the transport device 24 and thus to check the accuracy of the width adjustment or intake width AB.

[0155] Furthermore, the test system can have a reference mark 35, as shown in Figs. 7a and 7b, which can be detected by a sensor 23 of the transport vehicle 7. By detecting and evaluating the reference mark 35, it can be verified whether the reference mark 35 is detectable by the transport vehicle 7. If the reference mark 35 is not detected, then, for example, maintenance is required with regard to the sensor 23.

[0156] To check the setting of the intake width AB, the test system can have a (further / fourth) locking device by means of which the width adjustment of the transport device 24, in particular its unit load transfer means 27, can be locked. This can, for example, also be implemented, as shown in Fig. 7a, by the obstruction 33 or, as shown in Fig. 7d, by a hatched standard unit load S, i.e., a unit load S or block of a standard size, against which the transport device 24 can be positioned. The intake width AB set in this way can be compared with the actual width of the obstruction 33 and / or the standard unit load S. A deviation from this again indicates a need for maintenance of the transport vehicle 7.

[0157] Markings can be arranged in the storage rack 3 and / or on the individual items S arranged in the storage rack 3, which, for example, enable the identification of the respective item S. These markings can be designed, for example, as an optically detectable code (barcode, QR code, etc.). The sensor 23 of the transport vehicle 7 is designed as a reader corresponding to the marking. To test the sensor 23, the test system for optical interaction can be provided with a reference marking 35 arranged in the storage rack 3. The reference marking 35 can be detected by the sensor 23 for marking detection and evaluated by the evaluation system 38, whereby the detectability value is determined and compared with a target value range for the detectability value.If the detectability of the reference mark 35 deviates from the target value range, for example due to too frequent errors, then maintenance is required with regard to the sensor 23.

[0158] Finally, it is also noted that the scope of protection is defined by the patent claims. However, the description and drawings must be used to interpret the claims. Individual features or combinations of features from the different embodiments shown and described can, in themselves, represent independent inventive solutions.

[0159] It is specifically noted that the depicted devices may in reality comprise more or fewer components than shown. In some cases, the depicted devices or their components may also be shown not to scale and / or enlarged and / or reduced in size.

[0160] Reference numeral list

[0161] 1 Storage system S general cargo

[0162] 2 racking unit FE driving level

[0163] 3 Storage rack RE shelf level

[0164] 4 Shelf aisle UE Transfer level

[0165] 5 Leadership system SZ safety zone

[0166] 6 guide rails WAP maintenance area

[0167] 7.7' (replacement) transport vehicle a swivel angle

[0168] 8 Lifting device

[0169] 9 Maintenance vehicles

[0170] 10 Maintenance vehicle pickup unit

[0171] 11 Limitation

[0172] 12 Passage

[0173] 13th round

[0174] 14 Monitoring system

[0175] 15 Buffer system

[0176] 16 Supporting structure

[0177] 17 Lifting drive

[0178] 18 Lifting device - receiving unit

[0179] 19a first recording unit

[0180] 19b second recording unit

[0181] 20 basic frames

[0182] 21 wheel

[0183] 22 Drive system

[0184] 23 Sensors

[0185] 24 Transport device

[0186] 25 Extension drive

[0187] 26 piecework

[0188] 27 general cargo handling equipment

[0189] 28 B wide- S adjusting device

[0190] 29 Transport organ

[0191] 30 busbar

[0192] 31 current collectors

[0193] 32 Warning contact

[0194] 33 Disturbance Structure

[0195] 34 Stop element

[0196] 35 Reference marking

[0197] 36 Control unit

[0198] 37 recording units

[0199] 38 From value unit

[0200] 39 S control s sy stem

[0201] 40 Drive shaft

[0202] 41 shelf supports

[0203] 42 Swivel drive

[0204] AB recording width

Claims

P a t e n t a n s p r ü c h e 1. Storage system (1) for storing unit loads (S), comprising several adjacent aisle units (2), each comprising two longitudinally extending and parallel storage racks (3) with shelf surfaces arranged in superimposed rack levels (RE), a rack aisle (4) between the storage racks (3), a guide system (5) arranged in superimposed travel levels (FE) in the rack aisle (4) and running along the storage racks (3), at least one automated transport vehicle (7) for placing unit loads (S) into the storage racks (3) and retrieving unit loads (S) from the storage racks (3), which is movable in the rack aisle (4) along the guide system (5), and a lifting device (8) for transferring the at least one transport vehicle (7) between the travel levels (FE) and a transfer level (UE).at least one maintenance workstation (WAP) for servicing the at least one transport vehicle (7) by a person and / or a maintenance robot, and at least one autonomously moving maintenance vehicle (9), which has a maintenance vehicle receiving unit (10) for receiving the at least one transport vehicle (7) and is designed for transporting the at least one transport vehicle (7) between the lifting device (8) and the at least one maintenance workstation (WAP), characterized in that the storage system (1) comprises a safety zone (SZ) surrounded by a boundary (11), which extends over the several adjacently arranged rack aisle units (2) and in which the lifting devices (8) of the rack aisle units (2) are arranged, wherein the maintenance workstation (WAP) is arranged outside the safety zone (SZ) and the boundary (11) has a passage (12) passable by the at least one maintenance vehicle (9),via which at least one autonomously moving maintenance vehicle (9) can enter and / or leave the safety zone (SZ).

2. Storage system (1) according to claim 1, characterized in that the boundary (11) has a passage (13), in particular a lockable passage, through which a person can enter and / or leave the safety zone (SZ).

3. Storage system (1) according to claim 1 or 2, characterized in that the storage system (1) additionally comprises a monitoring system (14) which is configured to monitor the integrity of the safety zone (SZ) and to generate and transmit a stop signal as a result of a violation of this integrity, and a control system associated with the safety zone (SZ) which comprises a receiving unit for receiving the stop signal and is configured to stop the lifting devices (8) and / or maintenance vehicles (9) located in the safety zone (SZ) as a result of receiving the stop signal by the receiving unit.

4. Storage system (1) according to claims 2 and 3, characterized in that the monitoring system (14) has a monitoring device associated with the passage (13), which includes a transmitting unit and is configured to detect a violation of passage integrity and to send a stop signal by means of the transmitting unit as a result of a detected violation of passage integrity.

5. Storage system (1) according to claim 3 or 4, characterized in that the monitoring system (14) has a monitoring device associated with the boundary (11), which includes a transmitting unit for sending the stop signal and is configured to detect a passage of the boundary (11), in particular by an entity, and to send the stop signal to the receiving unit of the control system by means of the transmitting unit, in particular as a result of a passage of the boundary (11).

6. Storage system (1) according to one of claims 3 to 5, characterized in that the monitoring system (14) has a monitoring device associated with the passage (12), which includes a transmitter unit for sending the stop signal and is configured to detect the passage (12) being passed by an entity and to check whether the entity passing the passage (12) is a maintenance vehicle (9), and to send the stop signal to the receiver unit of the control system by means of the transmitter unit, in particular as a result of the passage (12) being passed by an entity other than a maintenance vehicle (9).

7. Storage system (1) according to one of claims 1 to 6, characterized in that the boundary (11) comprises a structural boundary (11), in particular a protective fence, and / or an optical boundary (11), in particular a boundary line, and / or a virtual boundary (11).

8. Storage system (1) according to one of claims 1 to 7, characterized in that the lifting device (8) has a vertical support structure (16) and the at least one maintenance vehicle (9) is designed to move along the vertical support structure (16) in order to align the maintenance vehicle receiving unit (10) on one of the driving planes (FE).

9. Storage system (1) according to one of claims 1 to 7, characterized in that the lifting device (8) has a vertical support structure (16) and a lifting device receiving unit (18) mounted vertically on the vertical support structure (16) via a lifting drive (17) for receiving at least one transport vehicle (7).

10. Storage system (1) according to claim 9, characterized in that a buffer system (15) is provided on the lifting device (8) for taking over at least one transport vehicle (7) from the lifting device (8) and transferring the at least one transport vehicle (7) to a maintenance vehicle (9) and / or for taking over at least one transport vehicle (7) from a maintenance vehicle (9) and transferring the at least one transport vehicle (7) to the lifting device (8).

11. Storage system (1) according to claim 9 or 10, characterized in that the lifting device receiving unit (18) and the maintenance vehicle receiving unit (10) comprise coupling elements that can be engaged with each other, by means of which the at least one maintenance vehicle (9) can be positioned relative to the lifting device receiving unit (18) and preferably locked in a docking position.

12. Storage system (1) according to one of claims 9 to 11, characterized in that the lifting device receiving unit (18) comprises guide rails (6) arranged in pairs for the at least one transport vehicle (7).

13. Storage system (1) according to one of claims 9 to 12, characterized in that the lifting device receiving unit (18) has a first receiving unit (19a) and a second receiving unit (19b) arranged above the first receiving unit (19a) for receiving one transport vehicle (7) each, which preferably each comprise guide rails (6) arranged in pairs for the transport vehicles (7).

14. Storage system (1) according to one of claims 1 to 13, characterized in that the maintenance vehicle receiving unit (10) comprises guide rails (6) arranged in pairs for the at least one transport vehicle (7).

15. Storage system (1) according to one of claims 1 to 14, characterized in that the maintenance vehicle receiving unit (10) has a first receiving unit (19a) and a second receiving unit (19b) arranged above the first receiving unit (19a) for receiving one transport vehicle (7) each, which preferably each comprise guide rails (6) arranged in pairs for the at least one transport vehicle (7).

16. Bearing system (1) according to one of claims 1 to 15, characterized in that the guide system (5) comprises guide rails (6) arranged in pairs in the travel planes (FE) for the at least one transport vehicle (7).

17. Storage system (1) according to one of claims 1 to 16, characterized in that at least one of the rack aisle units (2), in particular several or all rack aisle units (2), of the storage system (1) is designed according to one of claims 18 to 38.

18. Rack aisle unit (2) for a storage system (1), in particular for a storage system (1) according to one of claims 1 to 17, comprising two longitudinally extending and parallel storage racks (3) with storage compartments arranged in superimposed rack levels (RE), a rack aisle (4) between the storage racks (3), a guide system (5) which is arranged in one or more driving levels (FE) in the rack aisle (4) and runs along the storage racks (3), and at least one automated transport vehicle (7) for storing unit loads (S) in the storage racks (3) and retrieving unit loads (S) from the storage racks (3), which is movable in the rack aisle (4) along the guide system (5), wherein the at least one transport vehicle (7) comprises a transport device (24) extendable by means of an extension drive (25) for transferring unit loads (S) between the storage rack (3) and the transport vehicle (7), several running wheels (21) and a drive unit (22) coupled to at least one of the running wheels (21), characterized in that a detection system for detecting at least one analysis parameter of the at least one transport vehicle (7) is provided, which is connected to an evaluation system for comparing the at least one analysis parameter with at least one analysis parameter-specific target value range, wherein the evaluation system is configured toto classify the transport vehicle (7) as requiring maintenance if at least one analysis parameter deviates from at least one respective target value range.

19. Rack aisle unit (2) according to claim 18, characterized in that the at least one transport vehicle (7) has a detection unit (37) of the detection system arranged on it.

20. Rack aisle unit (2) according to claim 18 or 19, characterized in that the at least one transport vehicle (7) has an evaluation unit (38) of the evaluation system arranged on it.

21. Rack aisle unit (2) according to one of claims 18 to 20, characterized in that the at least one analysis parameter comprises at least one drive analysis parameter selected from the group revolutions of the drive (22), motor current of the drive (22), toothed belt tension of the drive (22) and rotation of a drive shaft (40) of the transport vehicle (7), and / or at least one wheel analysis parameter selected from the group revolutions of the wheels (21) per unit distance, vibrations of a wheel bearing.

22. Rack aisle unit (2) according to one of claims 18 to 21, characterized in that the transport vehicle (7) has drive shafts (40) coupled to the drive unit (22), on which running wheels (21) are mounted and the drive unit (22) can be selectively switched to a driving mode in which the drive shafts (40) are rotated in the same direction of rotation or to an analysis mode in which drive shafts (40), in particular in pairs, are rotated in different directions of rotation.

23. Rack aisle unit (2) according to one of claims 18 to 22, characterized in that the at least one analysis parameter comprises at least one extension analysis parameter selected from the group consisting of the holding force acting on the transport device (24) during extension, the motor current of the extension drive (25) and the number of motor revolutions of the extension drive (25) up to a blockage of the extension drive (25).

24. Shelf aisle unit (2) according to one of claims 18 to 23, characterized in that the transport device (24) has at least one transport element (29) arranged on it which can be pivoted out by means of a pivoting drive (42) for the positive-locking transport of the unit goods (S).

25. Rack aisle unit (2) according to claim 24, characterized in that the at least one analysis parameter has at least one swivel analysis parameter selected from the group motor current of the swivel drive (42), motor revolution speed of the swivel drive (42) up to a blockage of the swivel drive (42) and swivel angle (a) of the transport elements (29).

26. Rack aisle unit (2) according to one of claims 18 to 25, characterized in that a test system for physical interaction, in particular for mechanical, electrical and / or optical interaction, with the transport vehicle (7) is provided, wherein the test system is assigned to at least one of the driving levels (FE).

27. Shelf aisle unit (2) according to claim 26, characterized in that the test system has a blocking device for blocking a pivoting movement of the at least one transport element (29).

28. Rack aisle unit (2) according to claim 26 or 27, characterized in that the test system has a blocking device for blocking a movement of the transport device (24) along an extension direction.

29. Rack aisle unit (2) according to one of claims 26 to 28, characterized in that the test system has a blocking device for blocking a travel movement of the transport vehicle (7) along the longitudinal direction of the storage rack (3).

30. Rack aisle unit (2) according to one of claims 18 to 29, characterized in that the transport device (24) has a receiving platform which has a receiving width (AB) and on which at least one item (S) can be positioned, and / or Unit load transfer means (27), which are arranged parallel to each other and spaced apart by a receiving width (AB), such that at least one unit load (S) can be positioned between the unit load transfer means (27), and a width adjustment device (28), by which the receiving width (AB) for the at least one unit load (S) can be adjusted, wherein the at least one analysis parameter includes a set receiving width.

31. Rack aisle unit (2) according to claims 26 and 30, characterized in that the test system has a blocking device for blocking a width adjustment for the receiving platform and / or for the unit load transfer means (27).

32. Rack aisle unit (2) according to one of claims 18 to 31, characterized in that the at least one transport vehicle (7) has a sensor (23) for detecting markings in the storage rack (3), and an evaluation unit for evaluating the detected markings, wherein the at least one analysis parameter comprises a detectability value which indicates a measure for the detectability of the detected reference marking (35).

33. Shelf aisle unit (2) according to claims 26 and 32, characterized in that the test system comprises at least one reference marking (35) that can be detected optically by the transport vehicle (7).

34. Rack aisle unit (2) according to one of claims 18 to 33, characterized in that the rack aisle unit (2) comprises a power supply for the at least one transport vehicle (7).

35. Rack aisle unit (2) according to claim 34, characterized in that the energy supply comprises an energy storage device arranged on the transport vehicle (7), in particular a rechargeable one, wherein the at least one analysis parameter includes a capacity of the energy storage device.

36. Rack aisle unit (2) according to claim 34 or 35, characterized in that the power supply for each driving level (FE) has a conductor rail (30) arranged on the storage rack (3) and a current collector (31) arranged on the at least one transport vehicle (7) for electrical contacting the respective conductor rail (30).

37. Shelf aisle unit (2) according to claim 36, characterized in that the current collector (31) has a warning contact (32), wherein the at least one analysis parameter comprises a contacting value of the warning contact (32) by the busbar (30).

38. Rack aisle unit (2) according to claim 36 or 37, characterized in that data transmission between a higher-level control system (39) and the transport vehicle (7) takes place via the power supply and / or a wireless connection and the at least one analysis parameter comprises a parameter relating to the quality of the data transmission.

39. Method for the automated operation of a storage system (1) according to one of claims 1 to 17, wherein a transport vehicle (7) to be serviced is attached to the Maintenance workstation (WAP) provided and serviced at by a person or a maintenance robot, characterized by the steps: i) providing an autonomously moving maintenance vehicle (9) at the lifting device (8), ii) transferring a “service-required” transport vehicle (7) from its respective driving level (FE) to a height level of the transfer level (UE) by means of the lifting device (8), and iii) transporting the transport vehicle (7) from the lifting device (8) to the maintenance workstation (WAP) by means of the maintenance vehicle (9), wherein the maintenance vehicle (9) leaves the safety zone (SZ) via the passage (12).

40. Method according to claim 39, characterized in that the storage system (1) is configured according to claim 8, wherein the transport vehicle (7) is transferred in step ii) by moving the maintenance vehicle (9) along the vertical support structure (16) to the respective driving level (FE) and aligning the maintenance vehicle receiving unit (10) on the respective driving level (FE), transferring the "maintenance-requiring" transport vehicle (7) from the guide system (5) to the maintenance vehicle receiving unit (10) and subsequently moving the maintenance vehicle (9) along the vertical support structure (16) together with the "maintenance-requiring" transport vehicle (7) to the transfer level (UE).

41. Method according to claim 39, characterized in that the storage system (1) is configured according to claim 9, wherein the transport vehicle (7) is transferred in step ii) by aligning the lifting device receiving unit (18) on the respective travel level (FE) by means of the lifting drive (17), transferring the "maintenance-requiring" transport vehicle (7) from the guide system (5) to the lifting device receiving unit (18), aligning the lifting device receiving unit (18) together with the "maintenance-requiring" transport vehicle (7) on the transfer level (UE) and transferring the "maintenance-requiring" transport vehicle (7) from the lifting device receiving unit (18) to the maintenance vehicle receiving unit (10).

42. Method according to one of claims 39 to 41, characterized in that in step i) the autonomously movable maintenance vehicle (9) at the maintenance vehicle- In the receiving unit (10) a replacement transport vehicle (7) (7') is provided, which in step ii) is handed over to the guidance system (5) in the respective driving level (FE) after the transport vehicle (7) requiring maintenance has been taken over from the respective driving level (FE).

43. Method according to one of claims 39 to 42, characterized in that the Eager system (1) is configured according to claim 17, wherein one of the transport vehicles (7) is classified as requiring maintenance by the control unit (36), in particular according to a method according to one of claims 45 to 54, if the analysis parameter or at least one of the analysis parameters deviates from the respective analysis parameter-specific target value range.

44. Method according to one of claims 39 to 43, characterized in that a transport vehicle (7) is provided at the maintenance site, in particular only if it has been classified as requiring maintenance.

45. Method for determining the need for maintenance of a transport vehicle (7) in a racking unit (2) according to one of claims 18 to 38, wherein at least one analysis parameter of the transport vehicle (7) is recorded by means of the detection system and transmitted to the evaluation system, the recorded analysis parameter is compared by the evaluation system with the analysis parameter-specific target value range and the transport vehicle (7) is classified as requiring maintenance if the analysis parameter deviates from the respective target value range.

46. ​​Method according to claim 45, characterized in that the rack aisle unit (2) is designed according to claim 21, wherein at least one drive analysis parameter and / or at least one wheel analysis parameter is acquired by means of the acquisition system.

47. Method according to claim 46, characterized in that the transport vehicle (7) is moved by the drive (22) over a unit distance along the rack aisle (4), wherein a number of revolutions of the wheels (21) achieved in this process is recorded in order to determine the number of revolutions of the wheels (21) per unit distance, after which the The detected number of revolutions is compared by the control unit (36) with a target value range for the number of revolutions.

48. Method according to one of claims 45 to 47, characterized in that the rack aisle unit (2) is designed according to claim 22, wherein the drive unit (22) of the transport vehicle (7) is switched into analysis mode, a rotation of the drive shafts (40) achieved in this way is detected and compared by the control unit (36) with a setpoint range for the rotation of the drive shafts (40).

49. Method according to one of claims 45 to 48, characterized in that the rack aisle unit (2) is designed according to claims 25 and 27, wherein the at least one transport element (29) is aligned and pivoted out on the blocking device to block the pivoting movement until the pivoting movement is blocked, and wherein at least one pivot analysis parameter is detected and compared with a target value for the at least one pivot analysis parameter.

50. Method according to one of claims 45 to 49, characterized in that the rack aisle unit (2) is designed according to claim 28, wherein the transport device (24) is extended by the extension drive (25) in the direction of the blocking device, wherein at least one extension drive parameter is detected and compared with a setpoint range for the at least one extension drive parameter.

51. Method according to one of claims 45 to 50, characterized in that the rack aisle unit (2) is designed according to claim 29, wherein the transport vehicle (7) is driven by the drive unit (22) and is moved in the direction of the blocking device to block the travel movement until the travel movement is blocked by the blocking device, wherein a drive parameter is detected and compared with a setpoint range for the drive parameter.

52. Method according to one of claims 45 to 51, characterized in that the shelf aisle unit (2) is configured according to claim 33, wherein the reference marking (35) is detected by means of the sensor (23) for detecting markings and by the The evaluation system is evaluated, whereby the detectability value is determined and compared with a target value range for the detectability value.

53. Method according to one of claims 45 to 52, characterized in that the shelf aisle unit (2) is designed according to claim 37, wherein the contact s value is detected by the detection system and compared by the evaluation system with a target value range for the contact s value.

54. Method according to one of claims 45 to 53, characterized in that the shelf aisle unit (2) is designed according to claim 38, wherein the parameter relating to the quality of the data transmission is recorded by means of the detection system and compared with a target value range for the quality of the data transmission by means of the evaluation system.

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