Grid verification tool, system and method

Abstract

A tool, system and method for verifying structural alignment and elevation of a grid framework structure. The system comprising the grid levelness verification tool for surveying a grid framework structure, at least one surveying instrument, the tool and surveying instrument being configured for an operator to carry out the method.

Description

[0001] Grid verification tool, system and method

[0002] Field

[0003] The present disclosure relates to a device and method for surveying a structure and verifying the levelness of the structure. In particular, the device or tool may be used to survey a grid framework structure to verifying structural alignment and elevation of a grid framework structure for an automated storage and retrieval system.

[0004] Background

[0005] Some commercial and industrial activities require systems that enable the storage and retrieval of a large number of different products. W02015019055A1 describes a storage and retrieval system in which stacks of storage containers are arranged within a grid framework structure. The storage containers are accessed from above by load handling devices operative on rails or tracks located on the top of the grid framework structure.

[0006] The grid framework structure is required to be correctly aligned and level to allow load handing devices to operate at speed and in close proximity. Achieving a high level of precision when building the grid framework structure takes time and it is expensive to build. Once the structure is erected, in order to avoid problems with running the load handling devices, it is important to check the levelness of the supports for the tracks, as well as whether the grid is square or has skews, twists etc. before the system may be put into operation.

[0007] Structures are typically surveyed at the top-level, moving across the grid. For example, a jig may be placed by an operator over track intersections or nodes. The jig may be a hand-placed jig. Where the structure is sufficiency robust, the operator may walk on top of the structure to place the jig. For other structures, this might not be possible and a cherry picker or similar equipment must be used.

[0008] However, this represents a number of challenges:

[0009] • Safety concerns over people working at height. Typically, such structures may be 8m or more above ground level.

[0010] • Working at height is typically slower due to the safety procedures that must be followed.

[0011] • The weight of people working and moving on the top level of the grid framework structure may distort the grid framework structure.

[0012] • It is difficult to move equipment at height and it is difficult to move equipment on the grid framework structure.

[0013] • It is difficult to move equipment beneath the top level, due to having to navigate around support columns.

[0014] • It may be difficult to reach all intersections of the grid framework structure.

[0015] It will be appreciated that together these challenges are potentially time-consuming and represent a dangerous process.

[0016] To avoid these challenges, some storage and retrieval systems have been designed to be less precise and therefore avoid the need for structure verification. However, these systems lose efficiency in operation of the system from being designed this way.There is therefore a need for a device that may be used to safely and easily measure the grid framework structure and verify the alignment, elevation, and levelness of the grid framework structure.Summary

[0017] The disclosure is defined in the accompanying claims.

[0018] Device

[0019] A grid levelness verification tool is provided, for surveying a grid framework structure, for an automated storage and retrieval system, the grid framework structure comprising a first set of parallel track supports and a second set of parallel track supports extending substantially perpendicularly to the first set of parallel track supports in a substantially horizontal plane to form a grid comprising a plurality of grid spaces, wherein the grid is elevated and supported by a set of uprights, the tool comprising:

[0020] a jig having a body comprising a platform arranged in a first plane, and means for orientating the platform on a track support;

[0021] a reflector fixedly mounted to the upper surface of the platform, the reflector being substantially exposed to allow line-of-sight to the reflector;

[0022] a positioning means for positioning the jig on an intersection of the track supports; and

[0023] a sensor means for determining whether the jig is correctly oriented on the intersection.

[0024] The tool relates to a grid levelness verification tool designed for surveying the levelness of a grid framework structure in an automated storage and retrieval system. The grid framework structure comprises a first set of parallel track supports and a second set of parallel track supports extending perpendicular to the first set, forming a grid of multiple grid spaces. This grid is elevated and supported by uprights.

[0025] The grid framework structure forms a plurality of storage locations beneath the grid. Containers may be stacked between the uprights and be guided by the uprights in a vertical direction when lifted through the plurality of grid spaces.

[0026] Typically, a network of tracks forming a grid pattern are placed on the track supports. In this way, load handling devices may run on the automated storage and retrieval system. It is therefore important to verify that the grid is both level and square for unproblematic running of the load handling devices and more widely the automated storage and retrieval system.

[0027] The tool may be used before or after tracks are installed on the track supports. However, typically the tool is used on the grid framework structure before tracks and other installations are completed. The tool may be used throughout the installation process of the grid framework structure, to verify the grid levelness of the same track supports before and after the tracks are installed on the track supports.

[0028] The tool features a jig with a platform arranged in a horizontal plane, which can be oriented on a track support. A reflector is mounted on the upper surface of the platform and is exposed for unobstructed line-of-sight access. The reflector interacts with an external surveying instrument which takes a positional measurement. By using the positioning means to place the track support, distortion of the track grid framework structure is avoided.

[0029] The reflector may be a mirror or a prism.The tool comprises a sensor means to detect the correct positioning and orientation of the jig on the track supports. Typically, the jig will be positioned at or over track intersections, where the track supports in the first direction cross with the track supports in the second direction. Intersections are defined as the points where the first and second sets of track supports intersect.

[0030] The positioning means allows the jig to be placed on a structure, with minimal interaction with the structure itself.

[0031] Thus, a simple, lightweight and precise device is provided to verify the levelness of the grid framework for ensuring proper alignment and functionality in automated storage and retrieval systems.

[0032] The positioning means may comprise an extendable pole, a drone or other positioning arrangement. The pole may be telescopic, foldable or collapsible, and / or segmented, i.e. extendable by any suitable means.

[0033] An operator may position the jig on a structure using an extendable pole. Typically, the positioning means may be extended to 8m or more. In this way, the user may be positioned at ground level, while points of the structure are being measured at height. This provides the advantage of reducing the requirement to work at height, both in terms of safety, time and cost.

[0034] The positioning means may comprise a bridge substantially centrally mounted to the jig body at one end, wherein the distal end of the bridge extends beyond the edge of the platform, and the distal end has a connector for attaching the positioning means.

[0035] The bridge may comprise an arch, the arch having a cut-out around the reflector to allow line-of-sight to a surveying instrument.

[0036] The bridge is a structural component of the tool that is substantially centrally mounted to the jig body and extends outward from the platform. The distal end of the bridge is provided with a connector for connecting to the positioning means or pole. The central mounting of the bridge means that the tool is substantially balanced and therefore easier to position. This is particularly important when the positioning means or pole is extended. By design, the jig is also intended to remain more balanced and stable when the tool is placed on an intersection in order to take a positional measurement of the tool.

[0037] The bridge has an arched design, which incorporates a cut-out surrounding the reflector. This cutout ensures a wider field of vision for clear and unobstructed line-of-sight between the reflector and the surveying instrument, facilitating the ability for the surveying instrument to see the reflector at any intersection on the grid.

[0038] The bridge feature significantly improves the usability of the tool by combining stability, versatility, and unobstructed access for surveying operations.

[0039] In some arrangements, the bridge may be rotated relative to the reflector and thereby extend from a different side of the platform. For example, the bridge may be placed to extend from each side of the platform. This allows the jig to be positioned on any intersection, with the same face of the prism or reflector facing in the direction of the surveying instrument. Consistently takingmeasurements using the same face of the prism or reflector helps to maintain consistency in measurements.

[0040] In some arrangements, the jig may decouple from the pole. While the operator must keep the pole in their hands, it is important to minimise any forces exerted by the tool when a measurement is being taken. The operator may decouple the jig when it is positioned on or over an intersection to take a measurement in order to prevent the pole from impacting the measurement. After the measurement is taken, the jig may be recoupled to the pole.

[0041] The means for orientating the platform may be arranged to direct the platform into orientation over an intersection.

[0042] The means for orientating the platform on the track support may comprise legs extending in a downwards direction from the platform.

[0043] The means for orientating the platform may be integrated into the tool, and provides precise alignment and seating of the tool over intersections.

[0044] The means for orientating the platform may comprise four legs extending from the platform of the jig. Each of the legs may extend into a respective one of the four grid spaces adjacent to the grid intersection. The legs provide stability and facilitate accurate positioning of the platform over grid intersections.

[0045] Each leg may be tapered, allowing for easy insertion and precise alignment and seating over the intersection points of the track supports. This design minimizes the likelihood of misalignment during placement, and, under gravity, the arrangement of legs is designed to urge the tool into a seated position over the intersection.

[0046] The legs may extend downwardly from the corners of the platform. This placement of the legs enhances the stability of the jig by providing a balanced contact with the track supports.

[0047] Further, the legs may flare outward horizontally from the platform, which again aids in guiding the jig into position and provides a secure fit over the grid intersections. This design feature improves the efficiency of quickly and accurately positioning the tool, and reduces manual adjustments. These means for orientating the platform ensure that the platform of the jig is reliably positioned and aligned over grid intersections, facilitating accurate surveying and levelness verification of the grid framework structure.

[0048] The sensor means may comprise six point sensors, where three of the six point sensors are arranged in a first plane and extend substantially perpendicularly from the lower surface of the platform; and where the remaining three of the six point sensors are arranged in a second plane and a third plane, the second plane and the third plane being orthogonal to the first plane, and the third plane being orthogonal to the first and second plane.

[0049] The six-point locating principle is a fundamental concept used in mechanical design and jig design, to accurately and securely position a part or component in space. It ensures that the part is fully constrained with six points of contact, eliminating any degrees of freedom while maintaining stability.The first three locating points establish translational position in x-, y-, and z-directions and establish a reference plane, corresponding to the first plane. If the grid intersection point is level then the first plane will be precisely horizontal.

[0050] Two additional locating points are placed on a vertical face perpendicular to the first plane and establishes translation along the Y-axis and rotation around the Z-axis. The final locating point is placed on another vertical face, perpendicular to both the first and second planes. This point constrains the last degree of freedom: translation along the X-axis. These determine whether the intersection is square.

[0051] The arrangement of the six sensors on the tool simplifies positioning of the tool and ensures that measurements taken from the tool are repeatable and precise for each location the tool is positioned at, so that they may be directly compared.

[0052] The sensor means may comprise proximity sensors such as inductive proximity sensors or capacitive proximity sensors. The sensor means may comprise as piezo electric sensors. Any sensor detection means may be used. For example, microswitches or pushpins may be suitable. A pushpin may be used in combination with a piezoelectric of capacitive sensor, for example, to convert the applied mechanical force into an electrical signal.

[0053] The sensor means may provide a first output to an indicator means to indicate that the jig is orientated on the intersection.

[0054] The indicator means may comprise one or more indicator lights. In this way, an operator may be able to confirm when the tool has been positioned on the intersection.

[0055] The indicator means may comprise six indicator lights, corresponding to each of the six point sensors. Thus, the operator may be able to confirm when the tool has reached a stable and accurate position on the intersection, ready for a measurement to be taken by the surveying instrument.

[0056] The indicator means may be able to indicate an intermediate position, where only some of the point sensors are in touch with the track structure, or where the point sensors are in close proximity of the track structure.

[0057] Of course, it will be appreciated that the tool may indicate the readiness for taking a measurement in any other suitable way. Further, the indication may be automated.

[0058] The jig, save for the bridge, is substantially rotationally symmetrical and may be used in any orientation that has line-of-sight to the surveying instrument.

[0059] System

[0060] A system is provided for verifying structural alignment and elevation of a grid framework structure for an automated storage and retrieval system, the system comprising the grid levelness verification tool for surveying a grid framework structure as described above, and at least one surveying instrument, the tool and surveying instrument being configured to carry out the method described below.

[0061] As noted above, the grid levelness verification tool may be used for verifying the structural alignment and elevation of a grid framework structure used in an automated storage and retrievalsystem. The system integrates a grid levelness verification tool and at least one surveying instrument, collectively enabling precise measurement and analysis of the grid framework structure. The grid levelness verification tool is positioned over an intersection of grid framework structure track supports and has means for positioning and orientating the tool. The surveying instrument is located in the vicinity of the grid framework structure, preferably, approximately at the same elevation as the top level of the grid framework structure and is configured to interact with the grid levelness verification tool, via line-of-sight. The surveying instrument is capable of obtaining a location measurement of the grid levelness verification tool using the reflector of the tool.

[0062] Surveying instruments may be total stations, laser levels, or other optical devices, or any other instruments suitable for precision surveying.

[0063] A total station or total station theodolite is an optical instrument typically used for surveying and in building construction, to measure both vertical and horizontal angles and the slope distance from the instrument to a fixed, visible point. The instrument integrates the functions of an electronic theodolite and an electronic distance measurement (EDM) device. Measurements of positions in three-dimensional space are collected with high accuracy and triangulation calculations are performed.

[0064] An electronic theodolite is an angular measurement system that determines horizontal and vertical angles with precision using encoders or similar technologies, and the EDM system measures the distance to a target point by emitting a laser, infrared, or microwave signal and calculating the time it takes for the signal to reflect back to the instrument. The total station may have a built-in microprocessor to perform calculations, processes measurement data, and stores it for further use. Further, the total station may have the ability to connect to external devices.

[0065] Typically, the surveying instrument may be rotatably mounted on a tripod at a specific survey point or control point, allowing it to pivot and capture measurements of the tool relative to the control point in different directions.

[0066] The system ensures that any deviations in structural alignment and elevation may be detected and quantified.

[0067] The tool and surveying instrument each may further comprise communication means to send and receive communications from each other to each other, or to or from a central controller

[0068] The grid levelness verification tool and the surveying instrument are each equipped with communication means. These communication means enable data transmission between the tool and the surveying instrument, and / or to and from a central controller for centralized processing and control.

[0069] The communication means may comprise wireless communication, such as WiFi or cellular (4G, 5G) etc. Also, the communication means may comprise a simple visual indicator, such as a light source. Simple visual indicators are appropriate in cases where the communication is directly from the grid levelness verification tool and / or the surveying instrument to an operator.The tool communicates with the surveying instrument to take a measurement when the jig is correctly positioned on an intersection.

[0070] The tool may communicate with the surveying instrument to initiate a measurement automatically when the jig is correctly positioned over an intersection of the grid. Communication could be directly between the tool and the surveying instrument, or via a central controller.

[0071] At least one of the tool, the surveying instrument and the central controller may comprise means for recording positional measurements of the jig.

[0072] This enables data recording and logging for analysis, verification, and reporting.

[0073] The system may further comprise a device for indicating to an operator to move the jig to another intersection.

[0074] The system may comprise a device for indicating to an operator of the tool, when and where to move the jig to another intersection. This indication system improves efficiency by guiding the operator through the grid systematically, ensuring all necessary measurements are taken. This is intended to simplify manual operations, reducing errors and survey time.

[0075] The device may further indicate that measurements have been taken for all track support intersections.

[0076] A central controller allows for enhanced system management and data analysis.

[0077] Method

[0078] A method is provided, of verifying structural alignment and elevation of a grid framework structure for an automated storage and retrieval system, the grid framework structure comprising:

[0079] a first set of parallel track supports and a second set of parallel track supports extending substantially perpendicularly to the first set of parallel track supports in a substantially horizontal plane to form a grid comprising a plurality of grid spaces, wherein the grid is elevated and supported by a set of uprights, the method comprising:

[0080] a) extending a tool to orientate a jig supported by the tool above the grid framework structure;

[0081] b) positioning the jig on an intersection of the track supports;

[0082] c) determining, using sensor means, whether the jig is correctly oriented on the intersection, to generate a first output;

[0083] d) determining, using a surveying instrument, a positional measurement of the jig, to generate a second output; and

[0084] e) using the first and second outputs to verify the structural alignment and elevation of the intersection.The jig may indicate correct positioning on the grid framework structure when the first output shows that each of the orientation sensors is in contact with the grid framework structure.

[0085] A recording the positional measurement of the jig may be taken.

[0086] The method ensures precision in verifying the levelness, alignment, and positioning of the grid framework structure by employing a jig (of a grid levelness verification tool) and a surveying instrument, as discussed above.

[0087] The method involves extending a tool to position a jig above the grid framework structure and aligning the jig precisely over an intersection of the track supports. Sensor means on the jig determine whether the jig is correctly oriented on the intersection. A first output is generated when the sensor means confirms correct contact with the grid framework. A surveying instrument is used to measure the position and elevation of the jig at the intersection. This generates a second output providing precise positional data.

[0088] The first and second outputs are used in combination to verify the structural alignment and elevation of the grid intersection. The positional measurements of the jig may be recorded for further analysis, mapping, or reporting.

[0089] Although for most applications the track supports are arranged in a substantially horizontal plane, the method can also be applied to measuring the structural alignment of a grid of track supports in a non-horizontal plane.

[0090] The sensor means may comprise proximity sensors. The sensor means may comprise orientation sensors, for example accelerometers or gyroscopes. Alternatively, the sensor means may comprise any other sensor or combination of sensors that is suitable for determining whether the jig is correctly oriented over the intersection.

[0091] The method may further comprise the step of:

[0092] moving the jig to another intersection and repeating at least steps a)-e). The step may be repeated for each intersection of at least a portion of the grid, or for all intersections of the grid.

[0093] The jig is moved systematically by an operator to other intersections of the grid. Steps of positioning, orientation verification, measurement, and recording are repeated for each intersection. It will be appreciated, that the survey may be directed to a particular section of the grid, for example areas having different heights, or that will become different temperature zones.

[0094] The jig may be orientated in the same direction when measuring each intersection. The intersections may be mapped

[0095] The reflector is orientated in the same direction when measuring each intersection.

[0096] The jig remains orientated in the same direction during measurements to maintain consistency. In this way, any manufacturing imperfections in the reflector and or the jig will not impact on consistency of mapping of the grid framework structure.The intersections of the grid framework are mapped to provide a clear representation of the grid's structural alignment. This may identify areas of the grid that need to be adjusted before continued installation of the system.

[0097] The method may further comprise a preliminary step of setting up the surveying instrument at a survey or control point aside from the grid framework structure.

[0098] The surveying instrument may be located within line-of-sight of all or substantially all intersections of the grid framework structure.

[0099] Line-of-sight may be achieved directly, or wherein line-of-sight is achieved using one or more reflectors.

[0100] The surveying instrument is set up at a control point outside the grid framework structure. The survey instrument is maintained at the control point, and line-of-sight to all or substantially all grid intersections may be achieved either directly or using a mirror system to achieve visibility.

[0101] The method allows for accurate structural alignment and elevation verification, efficient and systematic measurement at multiple intersections to ensure full grid coverage, repeatability by consistent jig orientation and orientation on the track support intersections.

[0102] While the tool, method and system have been described in connection with a grid levelness verification tool. As noted above, the device may have a couple-decouple mechanism to detach the tool from the pole. This allows different types of tools to be attached to the pole. For example, in place of a grid levelness tool, a profiling tool may be coupled to the pole to check for step changes in track height. In another instance, the tool may comprise a camera to provide a visual inspection of the track. The couple-decouple mechanism may be of a type typically used for vacuum cleaner attachments, for example. Alternatively, the couple-decouple mechanism may comprise a clamp being a quick release arrangement or using nuts and bolts. The mechanism may use electromagnets, in order to be operated from a distance. Or the couple-decouple mechanism may be a simple rope connection.

[0103] It will be appreciated from discussion above that the tool, system and method provide an accurate, efficient, portable, cheap and safer way of verifying the structural alignment and levelness of the grid framework structure and particularly the track supports. The system improves accuracy as the verification tool is relatively light and avoids distortion of the structure when measurements are being taken. It also improves repeatability and reliability as the operator can tell if the jig has not seated correctly before measurements are taken.

[0104] In addition, the tool, method and system help to create a more reliable automated storage and retrieval system having reduced need for maintenance downtime. A more level track support may reduce fatigue of load handling devices thereby increasing the lifetime of the load handling device and or reducing energy usage of the load handling device in operation.Drawings

[0105] Further features and aspects of the present disclosure will be apparent from the following detailed description of illustrative embodiments made with reference to the drawings.

[0106] Figure 1 schematically illustrates a grid framework structure and storage containers.

[0107] Figure 2 schematically illustrates track on top of the grid framework structure illustrated in Figure 1. Figure 3 illustrates a prior art grid levelness verification tool. Figure 3(a) illustrates the upper-surface of the verification tool, and Figure 3(b) illustrates the under-surface verification tool.

[0108] Figure 4 illustrates perspective views a grid levelness verification tool. Figures 4(a) and 4(b) show two different perspectives.

[0109] Figure 5 is an exploded view of the tool shown in Figure 4.

[0110] Figure 6 illustrates the tool in use. Figure 6(a) shows an operator holding the extended pole, Figure 6(b) show the operator positioning the jig on the grid framework, and figure 6(c) shows a different view of the jig on the grid framework.

[0111] Figure 7 illustrates positioning the tool on a track support intersection. Vertical plane, horizontal plane and perspective views are shown. Figure 7(a) show the jig above the track support, in Figure 7(b) the jig has been lowered on to the intersection and in Figure 7(c) the jig is fully lowered onto the intersection.

[0112] Figure 8 illustrates the tool, with indicator means illuminated. Figure 8(a) is a plane view beneath the jig, Figure 8(b) is a perspective view of the jig and Figure 8(c) shows the jig on the grid framework.

[0113] Figure 9 illustrates a system of a grid levelness verification tool and a surveying instrument in use with a grid framework structure.

[0114] Figure 10 illustrate the tool, each of Figures 10(a), 10(b) and 10(c) show the bridge is at different orientations.

[0115] Figure 11 illustrates a drone arrangement of a grid levelness verification tool. Figure 11(a) shows the drone tool alone, and Figure 11(b) shows the drone on an intersection.

[0116] Figure 12 illustrates another alternative arrangement of a grid levelness verification tool. Figure 12(a) shows a lowered first pair of arms, and Figure 12(c) shows the same arrangement on track support. Figure 12(b) shows both pair of arms in a raised position, and Figure 12(d) shows the same arrangement on a track support.Detailed Description

[0117] Grid framework structure

[0118] Figure 1 illustrates a grid framework structure 1 comprising a supporting framework structure supporting a track structure 13. The supporting framework structure can take any suitable form. In the specific example illustrated in Figure 1, the supporting framework structure comprises a plurality of upright members 3 and horizontal members 5, 7 which are supported by the upright members 3. Upright members 3 may also be referred to as upright columns 3. The horizontal members 5 extend parallel to one another and the illustrated x-axis. The horizontal members 7 extend parallel to one another and the illustrated y-axis, and transversely to the horizontal members 5. The upright members 3 extend parallel to one another and the illustrated z-axis, and transversely to the horizontal members 5, 7. The horizontal members 5, 7 form a grid pattern defining a plurality of grid cells. At the top level, horizontal members 5, 7 form track supports. In the illustrated example, storage containers 9 are arranged in stacks 11 beneath the grid cells defined by the grid pattern, one stack 11 of storage containers 9 per grid cell.

[0119] Figure 2 shows a large-scale plan view of a section of track structure 13 forming part of the grid framework structure 1 illustrated in Figure 1 and located on top of the top level of horizontal members 5, 7 of the grid framework structure 1 illustrated in Figure 1. The track structure 13 may be provided by the horizontal members 5, 7 themselves (e.g. formed in or on the surfaces of the horizontal members 5, 7) or by one or more additional components mounted on top of the horizontal members 5, 7. The illustrated track structure 13 comprises x-direction tracks 17 and y-direction tracks 19, i.e. a first set of tracks 17 which extend in the x-direction and a second set of tracks 19 which extend in the y-direction, transverse to the tracks 17 in the first set of tracks 17. The first set of tracks 17 and the second set of tracks 10 meet at intersections 20 at the corners of the grid cells. In the illustrated example, intersections 20 are at the top of the upright members 3. The tracks 17, 19 define apertures 15 at the centres of the grid cells. The apertures 15 are sized to allow storage containers 9 located beneath the grid cells to be lifted and lowered through the apertures 15. The x-direction tracks 17 are provided in pairs separated by channels 21, and the y-direction tracks 19 are provided in pairs separated by channels 23. Other arrangements of track structure may also be possible.

[0120] As an alternative to the supporting framework structure as described with reference to Figure 1, in other examples the support framework structure comprises a plurality of prefabricated modular panels arranged in a grid pattern, the detail of which is described in WO2022034195A1, incorporated herein by reference. Any appropriate supporting framework structure can be used.

[0121] Prior art levelness toolFigure 3 illustrates a grid levelness verification jig 30 according to the prior art. Figure 3(a) illustrates the upper-surface 31 of the verification tool (jig) 30 which is substantially flat, and Figure 3(b) illustrates the under-surface 32 of the jig 30 which is molded to fit over a track intersection 20. In use, an operator walks out on the top level of the grid framework structure, and pushes the jig 30 onto a track intersection 20. The molding of the under-surface 32 is intended to be the inverse shape of the track intersection 20 so that the jig 30 is evenly supported by the track intersection 20, and so that the upper-surface 31 is substantially horizontal when positioned on the intersection 20.

[0122] A reflector (not shown) is attached to the flat upper-surface 31 of the jig so that a positional measurement may be taken by a surveying instrument situated at a control point within line-of-sight of the grid.

[0123] It will be appreciated that when working at the top level of the grid framework structure, which is likely to be several meters above floor level, the operator must employ significant safety measures which slows the process. Also, while the jig 30 is intended to be a snug fit over the intersection 20, there is no positive confirmation that the jig 30 is properly positioned and orientated on the intersection 20 -the process relies on the consistency of the operator positioning the jig.

[0124] Grid levelness verification tool

[0125] Figures 4(a), 4(b), and 5 illustrate a grid levelness varication tool 40, for surveying a grid framework structure of the type described above and shown in Figures 1 and 2. Of course the tool could be used on any type of structure with structural intersections.

[0126] The tool 40 has a jig 41 comprising a platform 42, 43 onto which other components are mounted. The platform 42, 43 defines a first plane. A reflector 44 is mounted substantially at the centre of the upper-surface 42 of the platform, and four legs 45 are mounted to under-surface 43, to extend downwards and outwards from the corners of the platform. The legs 45 are tapered towards the distal end.

[0127] Three sensors 46a are attached to the under-surface 43 of the platform in the first plane. A further two sensors 46b are attached to the leg mounts in a second plane, perpendicular to the first plane. A final single sensor 46c is attached to a leg mount a third plane, perpendicular to the first and second planes. Thus, together there are six sensors 46 and due the arrangement, the sensors 46 are able to resolve the orientation of the platform for all degrees of freedom. The sensors 46a, 46b, 46cmay be proximity sensors or orientation sensors or any other sensor that is able to determine whether the jig is correctly oriented over the intersection.

[0128] In use, the legs 45 enable the operator to guide the jig 41 roughly into position above the intersection. When in position above the intersection, the jig 41 may then be adjusted into its final position using the sensors 46a, 46b, 46c.

[0129] The tool 40 further comprises a bridge 47. The bridge 47 is substantially centrally mounted to the upper-surface 42 of the platform, and sits surrounding the reflector 44. The bridge 47 has an arched shape to extend from the centre of the platform to the side of the jig 41, and beyond the legs 45 at the distal end of the arch. In order to provide line-of-sight to the reflector, the bridge has a cut-out 48. As illustrated the cut-out 48 provides more than 180° visibility to the reflector 44.The distal end of the bridge 47 has a connector 50, for connecting an extendable pole 60 (shown in figure 6), and an indicator 49. The indicator 49 is connected to each of the sensors 46. It will be appreciated that the sensors 46 may be connected to the indicator 49 by any suitable means. As illustrated in figure 8, the indicator 49 comprises a series of lights 80.

[0130] As illustrated in Figures 6(a), 6(b) and 6(c), in use the tool 40 is attached to an extendable pole 60. An operator 61 extends the pole to reach the top level of a grid framework structure 62. The operator then stands inside the grid framework structure beneath the top level and positions the jig 41, through a grid cell, over an intersection of the track supports. The legs 45 of the jig extend through the four grid cells adjacent to the track support intersection. In this way, the operator 61 may position the tool 40 from ground level, and with minimal interference with the grid framework structure 62 itself.

[0131] Figure 7 illustrates positioning the jig 41 in more detail, and illustrates how the jig 41 orientates on the track supports. The illustrations of Figure 7 show vertical plane, horizontal plane and perspective views of the jig 41 over intersecting track supports 70.

[0132] In Figure 7(a) the jig 41 is above the track support 70 and the legs 45 on one side towards the distal end are touching the track support 70. As illustrated, the jig 41 is rotated relative to the support intersection.

[0133] The tapering of the legs 45 guide the jig 41 on to the intersection as the jig 41 is lowered.

[0134] As shown in Figure 7(b), from the position in Figure 7(a), the jig 41 has been lowered on to the intersection. In Figure 7(b) one side of the platform under-surface 43 is in contact with the track supports 70, and the jig 41 is slightly rotated compared with the intersection.

[0135] As shown in Figure 7(c), the jig 41 is fully lowered onto the intersection such that the platform 42, 43 is substantially level on the intersection and the platform 42, 43 is seated on the intersection. The jig 41 is substantially square with the intersection. In this orientation, each of the sensors 46 should be in contact with the intersection.

[0136] When the sensors 46 are in contact with the intersection, a signal or first output is sent to the indicator 49 and the lights 80 are illuminated, as shown in Figures 8(a), 8(b) and 8(c). The illuminated lights 80 allow the operator 61 to determine that the jig 41 is in position and in seated orientation on the intersection ready for a positional measurement of the jig 41 to be taken.

[0137] As shown in Figure 9, a surveying instrument 90 is positioned outside of the grid framework structure 62. The surveying instrument 90 is positioned at a survey or control point. The line 91 indicates line-of-sight between the reflector 44 and the surveying instrument 90. In the illustrated example, the surveying instrument 90 is located outside the grid framework structure 62 and slightly below the vertical level of the grid. In other examples, the surveying instrument 90 may be positioned above the level of the grid in order to more easily achieve line-of-sight to all intersections. When the jig 41 is in seated orientation on an intersection, a signal may be sent to the surveying instrument 90 to take a measurement of the position of the jig 41. The signal may be automated, semi-automated or the signal may be manual to a second operator (not shown) operating the surveying instrument 90. The surveying instrument 90 takes a measurement toestablish the position of the jig 41 and generates a second output. The measurement and output may be recorded.

[0138] The operator 61 can then move the jig 41 to another intersection and repeat the processes. In this way, the whole of the top level of the grid framework structure 62 may be measured. The recorded information together with knowing the control point may be processed and used to map the upper surface of the grid framework structure.

[0139] It will be understood that the sensors provide a relative location of the jig, and the positional measurement of by the surveying instrument provide an absolute location of the jig. In this way, the grid framework structure may be precisely surveyed, and structural alignment and elevation verified. As noted elsewhere in this disclosure, it is important for the reflector 44 to always be facing in the same direction with respect to the grid framework structure 62 and the surveying instrument 90 when taking measurements, in order to ensure that the same face is measured each time by the surveying instrument 90. This is for consistency of measurement, in case of any inconsistencies in the reflector 44. Considering Figure 9, when the operator 61 is situated inside the grid framework structure 62 and the surveying instrument 90 is at a static control point, it may not be possible for the tool 40 to reach all of the intersections without rotating the tool 40. For example, with the position of the pole 60 relative to the jig 41 as shown, the operator 61 would not be able to reach the rows of grid intersections farthest from the surveying instrument 90 around the edge of the grid while remaining inside the grid framework structure 62 and keeping the reflector facing in the same direction. In some examples, the operator may not be able to step out from under the grid framework structure 62 in order to use the tool 40 on the intersections at or near the edge of the grid, for example because a wall or column or other obstruction impedes access. To address this issue, the bridge 47 may be rotatably mounted to the jig 41, and fixable in specific orientations as required.

[0140] Accordingly, to reach all grid intersections, as illustrated in Figures 10(a), 10(b) and 10(c) the bridge 47 may be rotated relative to the jig platform 42, 43 and reflector 44. The arrow 100 marked on the upper-surface 42 of the platform provides the jig 41 with directional orientation. As may be seen, in Figure 10(a) the bridge 47 extends at 180° from the direction of the arrow 100, and in Figures 10(b) and 10(c) the bridge 47 extends at 180° + / - 45°from the direction of the arrow 100.

[0141] To further assist with providing a complete survey of all the grid framework structure intersections, and more particularly, ensuring line-of-sight from the jig 41 to the surveying instrument 90, the area may be set up with one or more fixed position mirrors or other reflectors (not shown) to direct the measurement light from and to the surveying instrument 90.

[0142] Figures 11(a) and 11(b) illustrate another example of a grid levelness verification tool 110. The tool comprises a drone 110 configured to carry a jig 141 above the grid framework structure 62. In this example, the pole positioning means, is replaced with the drone 110 itself. Otherwise, the tool 110 is similar to the tool 40. As illustrated, the drone 110 is in the shape of a cross with four transversely protruding arms, each arm comprising a propeller 111. Other arrangements are also possible.

[0143] In use, the drone 110 flies over the grid framework structure 62 and approaches an intersection from above. The drone 110 lowers the jig 141 onto the intersection. The legs 145 help to position the jig 141 on top of the intersection. When the drone 110 has settled on top of the intersection andis aligned, the measurement of grid levelness can be taken. The drone 110 can then take off and travel to another intersection. The drone 110 can be controlled remotely by an operator.

[0144] Figures 12(a), 12(b), 12(c) and 12(d) illustrate another example of a grid levelness verification tool 120. In this example, the tool 120 has two pairs of arms 121a and 121b. The first pair of arms 121a extending from a first pair of opposed sides of a jig 122, and the second pair of arms 121b extending from the second pair of opposed sides of jig 122. Each of the arms 121a, 121b are arranged to move between raised and lowered positions, pivoting about the mounting point. The arms 121 may be connected to the jig 122 via a hinge or other pivoting mechanism. At the distal end of each arm 121 is a pair of wheels. The wheels are shaped to engage with the tracks supports of the grid framework structure 62.

[0145] As illustrated in figure 12(a) the first pair of arms 121a are in the lowered position, while the second pair of arms 121b are in the raised position, and as illustrated in figure 12(b) both pairs of arms 121a, 121b are raised. Figure 12(c) illustrates the tool 120 as arranged in figure 12(a) position on a grid framework structure 62, and figure 12(d) illustrates the tool 120 as arranged in figure 12(b) positioned on a grid frame work structure 62.

[0146] When in the lowered position the wheels engage with the track supports and when in the raised position the jig 120 rests on the track supports. With the wheels engaged with the track supports, the tool 120 is able to move along the track supports. The tool 120 can change direction of travel by swapping the positions of the two pairs of arms 121a, 121b.

[0147] To take a measurement, both sets of arms 121a, 121b are raised to lift all of the wheels clear of the track supports. The jig 120 then settles on top of an intersection. As in previous examples, the jig 120 is provided with legs which help to locate and correctly position the jig on top of the intersection.

Claims

Claims1. A method of verifying structural alignment and elevation of a grid framework structure for an automated storage and retrieval system, the grid framework structure comprising:a first set of parallel track supports and a second set of parallel track supports extending substantially perpendicularly to the first set of parallel track supports in a substantially horizontal plane to form a grid comprising a plurality of grid spaces, wherein the grid is elevated and supported by a set of uprights, the method comprising:a) extending a tool to support and orientate a jig above the grid framework structure; b) positioning the jig on an intersection of the track supports;c) determining, using at least one orientation sensor means, whether the jig is correctly oriented on the intersection, to generate a first output;d) determining, using a surveying instrument, a positional measurement of the jig, to generate a second output; ande) using the first and second outputs to verify the structural alignment and elevation of the intersection.

2. A method according to claim 1, wherein the jig is correctly positioned on the grid framework structure when the first output shows that each of the orientation sensors is in contact with the grid framework structure.

3. A method according to any one of the preceding claims, further comprising the step of:f) recording the positional measurement of the jig.

4. A method according to any one of the preceding claims, further comprising the step of:g) moving the jig to another intersection and repeating at least steps a)-e).

5. A method according to claim 4, wherein step g) is repeated for each intersection of at least a portion of the grid.

6. A method according to claim 4 or 5, wherein the jig is orientated in the same direction when measuring each intersection.

7. A method according to any one of the preceding claims, wherein the intersections are mapped.

8. A method according to any one of the preceding claims, further comprising a preliminary step of setting up the surveying instrument at a survey or control point aside from the grid framework structure.

9. A method according to any one of the preceding claims, wherein the surveying instrument is located within line-of-sight of all or substantially all intersections of the grid framework structure.

10. A method according to claim 9, wherein line-of-sight is achieved directly, or wherein line-of-sight is achieved using one or more reflectors.

11. A grid levelness verification tool for surveying a grid framework structure, for an automated storage and retrieval system, the grid framework structure comprising a first set of parallel track supports and a second set of parallel track supports extending substantially perpendicularly to the first set of parallel track supports in a substantially horizontal plane to form a grid comprising a plurality of grid spaces, wherein the grid is elevated and supported by a set of uprights, the tool comprising:a jig having a body comprising a platform arranged in a first plane, and means for orientating the platform on a track support;a reflector fixedly mounted to the upper surface of the platform, the reflector being substantially exposed to allow line-of-sight to the reflector;a positioning means for positioning the jig on an intersection of the track supports; andat least one orientation sensor means for determining whether the jig is correctly oriented on the intersection.

12. A tool according to claim 11, wherein the reflector is a mirror or a prism.

13. A tool according to any one of claims 11-12, wherein the positioning means comprises an extendable pole.

14. A tool according to any one of claims 11-13, wherein the positioning means comprises a bridge substantially centrally mounted to the jig body at one end, wherein the distal end of the bridge extends beyond the edge of the platform, and the distal end has a connector for attaching the positioning means.

15. A tool according to claim 14, wherein the bridge comprises an arch, the arch having a cut-out around the reflector to allow line-of-sight to a surveying instrument.

16. A tool according to any one of claims 11-15, wherein the means for orientating the platform is arranged to direct the platform into orientation over an intersection.

17. A tool according to any one of claims 11-16, wherein the means for orientating the platform on the track support comprises legs extending in a downwards direction from the platform.

18. A tool according to any one of claims 11-17, wherein the sensor means provides a first output to an indicator means to indicate that the jig is orientated on an intersection.

19. A system for verifying structural alignment and elevation of a grid framework structure for an automated storage and retrieval system, the system comprising the grid levelness verification tool for surveying a grid framework structure according to any one of claims 11-18, and at least one surveying instrument, the tool and surveying instrument being configured for an operator to carry out the method of any one of claims 1-10.

20. A system according to claim 19, wherein the tool and surveying instrument each further comprise communication means to send and receive communications between each other, or to or from a central controller.

21. A system according to claim 20, wherein the tool communicates with the surveying instrument to take a measurement when the jig is correctly positioned on an intersection.

22. A system according to any one of claims 20-21, wherein at least one of the tool, the surveying instrument and the central controller comprises means for recording positional measurements of the jig.

23. A system according to any one of claims 20-22, wherein the system further comprises a device for indicating to an operator to move the jig to another intersection.

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