Bin stack leveling device and method

Abstract

A leveling device for analyzing inclination or deformations of a warehouse floor. The leveling device includes a frame having a lower surface, an upper surface, and four corners sized and arranged to sit on the floor and within an area corresponding to a single grid-cell of the grid-based storage structure, a dual-axis level coupled to the frame, and a plurality of adjustable leveling feet. The plurality of adjustable leveling feet being movable in a vertical direction, toward and away from the floor, to determine a height of the inclination or deformation of the floor about the X-axis and the Y-axis at a plurality of locations. The leveling device including a display arranged to display the plurality of heights to allow a user to take a corrective action to level the area.

Description

[0001] 127308-883732

[0002] BIN STACK LEVELING DEVICE AND METHOD CROSS REFERENCE

[0003] The present application claims priority to U.S. Provisional Application No. 63 / 778,944, filed on March 27, 2025, entitled BIN STACK LEVELING DEVICE AND METHOD, the entire contents of which is incorporated herein by reference.

[0004] TECHNICAL FIELD

[0005] The present disclosure relates to grid-based storage systems that house inventory items in bin stacks, and more particularly, to a leveling device for analyzing the inclination or deformation of a floor upon which the bin stacks rest and a method of using the leveling device. BACKGROUND OF THE INVENTION

[0006] Distribution fulfillment centers, such as warehouses, require systems that enable the efficient storage and retrieval of a large number of diverse products. Traditionally, inventory items are stored in containers, or bins, and arranged on rows of shelving on either side of an aisle. Each bin holds a plurality of items of one or more product types. The aisles provide access between the shelving for an operator or robot to migrate the aisles and retrieve the items. It is well understood that the aisles reduce the storage density of the system. In other words, the amount of space used for the storage of products (e.g., the shelving) is relatively small compared to the amount of space required for the storage system as a whole. As warehouse space is often scarce and expensive, alternative storage systems that maximize storage space are desired.

[0007] In one alternative approach, which offers a significant improvement in storage density, bins are stacked on top of one another and arranged in adjacent rows. That is, no aisle is provided between the adjacent rows of stacked bins. Thus, more bins, and in turn inventory, can be stored in a given space.

[0008] Various methods for retrieving inventory from the stacked bins have been contemplated. For example, U.S. Pat. Pub. No. 2021 / 0032034, which is incorporated by reference herein in its entirety, discloses a system in which bins are stacked and arranged in a plurality of rows underneath a grid, and the bins are retrieved by robots which subsequently pick and pack inventory items into order bins. While the system disclosed in U.S. Pat. Pub. No. 2021 / 0032034 automates much of the order fulfilment process, assembling the grid-based storage systems, and leveling the bins stacks, remains a labor intensive and costly process.BRIEF SUMMARY OF THE INVENTION

[0009] The leveling device disclosed herein analyzes the inclination or deformation of an area of a floor corresponding to a single grid-space and allows a worker to take corrective action that avoids the need for pouring and leveling an expensive new concrete floor. In one aspect of the present disclosure, the leveling device, includes: a frame having a lower surface and at least three vertices defining a plane, the frame being sized and arranged to sit on a floor and within an area corresponding to a single grid-cell of a grid-based storage structure; a level coupled to the frame; and a plurality of adjustable leveling posts coupled to the frame, each one of the plurality of adjustable leveling posts being movable in a vertical direction toward and away from the floor.

[0010] In some examples, the leveling device may be a dual-axis digital inclinometer. The plurality of adjustable leveling posts may include a first adjustable leveling post, a second adjustable leveling post, and a third adjustable leveling post. The first adjustable leveling post and the second adjustable leveling post may be located along a first midline of the level. The third adjustable leveling post may be located along a second midline of the level, the second midline being arranged perpendicular to the first mi dime. Each one of the plurality of adjustable leveling posts may include a rotatable knob to move the post in the vertical direction.

[0011] The leveling device may further include a plurality of height indicator displays. The plurality of height indicator displays may be coupled to the frame, each height indicator display may be arranged to display a distance between the floor and the lower surface of the frame at which that height indicator display is located. In some examples, each one of the plurality of height indicator displays may include a back plunger dial indicator and / or be oriented in an upward direction.

[0012] The leveling device may further include a zeroing block configured to zero the plurality of back plunger dial indicators. The leveling device may also include a handle.

[0013] The at least three vertices may define a convex hull polygon configured to contain a geometric center point of the single grid-cell.

[0014] In another aspect of the present disclosure, a leveling device, includes: a frame having a lower surface, an upper surface, and a plurality of comers, the frame being sized and arranged to sit on a floor within an area corresponding to a single grid-cell of a grid-based storage structure; a dual-axis level coupled to the frame; a first adjustable leveling post and a second adjustable leveling post provided along afirst midline of the dual-axis level, the first and second adjustable leveling posts being arranged to move in a vertical direction towards and away from the floor; athird adjustable leveling post provided along a second midline of the dual-axis level.the second midline extending perpendicular to the first midline, the third adjustable leveling post being arranged to move in the vertical direction towards and away from the ground; and a plurality of height indicator displays, each height indicator display being arranged to display a distance between the lower surface of the frame and the ground located directly underneath that respective height indicator display.

[0015] In yet another aspect, a bin stack leveling method includes the following steps: placing a lower surface of a frame including a level on the floor such that each comer of the frame is within an area corresponding to a single grid-cell of a grid-based storage structure; and an adjusting step, comprising adjusting a first adjustable leveling post, adjusting a second adjustable leveling post, and / or adjusting a third adjustable leveling post in a vertical direction until the frame is substantially level in a horizontal direction.

[0016] The adjusting step may include rotating the first adjustable leveling post, the second adjustable leveling post, and the third adjustable leveling post.

[0017] The method may further include: reading from a first height indicator display, a first distance between the lower surface of the frame and the floor located directly underneath the first height indicator display; reading from a second height indicator display, a second distance between the lower surface of the frame and the floor located directly underneath the second height indicator display; and reading from a third height indicator display, a third distance between the lower surface of the frame and the floor located directly underneath the third height indicator display.

[0018] The method may further include: gathering one a more first shims, a first summation of which is equal to the first distance; gathering one a more second shims, a second summation of which is equal to the second distance; and / or gathering one a more third shims, a third summation of which is equal to the third distance.

[0019] The method may also include removing the frame from the area and securing the one or more first shims, the one or more second shims, and / or the one or more third shims to the floor.

[0020] The method may further include placing the comers of the frame on at least one of the one or more first shims, the one or more second shims, or the at least one of the third shims; and verifying a levelness of the area.

[0021] BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic perspective view of a grid-based storage structure housing a plurality of bins in stacks.

[0022] FIG. 2A is partial perspective of the bin of FIG. 1.FIG. 2B is a side elevation view illustrating a process of stacking two bins of FIG. 2A.

[0023] FIG. 3 is a top elevation view of a single grid cell of the grid-based storage structure of FIG. 1. FIG. 4 is a perspective view illustrating bins stacked within a portion of the grid-based storage structure of FIG. 1.

[0024] FIG. 5 is a perspective view of a mobile robot including a picking arm and a grapple arranged to operate on top of the grid-based storage structure of FIG. 1.

[0025] FIG. 6 is a perspective view of a leveling device in accordance with an embodiment of the present disclosure.

[0026] FIG. 7 is a cross-section view of a portion of the leveling device of FIG. 6.

[0027] DETAILED DESCRIPTION

[0028] The technology disclosed herein relates to a leveling device for determining the inclination and / or deformation of a warehouse floor upon which a storage structure is deployed. As used herein, terms of orientation, for example, “vertical” and “horizontal,” or relative terms, such as “above,” “upwards,” “underneath,” and “downwards,” are used to describe the orientation or the relative position of an object in the normal gravitational frame of reference; that is, when the leveling device or the storage structure is resting on the warehouse floor. Also as used herein, the terms “substantially,” “generally,” and “about” are intended to mean that slight deviations from absolute are included within the scope of the term so modified.

[0029] FIG. 1 is a schematic illustration of a grid-based storage structure 10 according to an embodiment of the present disclosure. Storage structure 10 includes a framework 14 and a plurality of bins 100 configured to store inventory items (not shown) of one or more product types. Bins 100 preferably include cooperative nesting features that allow the bins to be stacked on top of one another to form stacks 12 that are efficiently housed within framework 14.

[0030] Framework 14 may include a plurality of vertical pillars 16 and a series of horizontal and perpendicularly arranged rails 22 supported by the pillars at an uppermost level of the framework. More specifically, pillars 16 form vertical shafts within which stacks 12 are housed, and rails 22 include a first set of rails 22a extending in a first direction (e.g., x-direction) and a second set of rails 22b extending in a second direction (y-direction) perpendicular to the first direction. For this reason, rails 22 may collectively be referred to as a grid 26, and the footprint of each vertical shaft may be referred to as a grid-space 27 (or “a grid-cell”). Grid 26 is designed to support and guide movement of robots 200 (FIG. 5) across the top of framew ork 14 as the robots' complete order fulfillment tasks.

[0031] With additional reference to FIGS. 2A and 2B, bins 100 may have a bottom 102, a sidewall 104 that defines an interior 106 configured to house the inventory items, and an “opentop” through which the inventory' items can be accessed. An upper end of sidewall 104, sometimes referred to as a rim 108, may have a chamfer 110 that is tapered inwardly toward the interior 106 of bin 100. Chamfer 110 may be designed to cooperate with an alignment feature 112 provided on the bottom 102 of another bin 100 to align and nest the bins in stacks 12.

[0032] Alignment feature 112 may extend from the bottom 102 of bin 100 and have a smaller surface area than the bottom of the bin. As a result, a ledge 114 is formed underneath sidewall 104 that extends about the perimeter of alignment feature 112. The chamfer 110 and alignment feature 112 are designed to cooperate with one another if the bins 100 are not aligned during a stacking process. For example, FIG. 2B illustrates a first bin 100a being lowered on top of a second bin 100b while the first bin is slightly offset to the right of the second bin. When the alignment feature 112 of first bins 100a is lowered into contact with the chamfer 110 of second bin 100b, the alignment feature of the first bin will slide along the chamfer and towards the interior 106 of the second bin to align the first and second bins relative to one another until the alignment feature of the first bin is nested within the rim 108 of the second bin, and the ledge 114 of the first bin sits on top of the rim of the second bin. It will be appreciated that the combination of chamfer 110, alignment feature 112, and ledge 114 allows bins 100 to be securely stacked upon one another and arranged within grid-cells 27.

[0033] FIG. 3 is a top-elevation view of a stack 12 housed within a single grid-cell 27. As illustrated, the cross-section of each grid-cell 27 is larger than the cross-section of bin 100. In this regard, when the stacks 12 of bins 100 are housed within framework 14, a small gap 18 exists around the entire perimeter of the bins. Put differently, the pillars 16 do not abut, or otherwise align or support, the stacks 12. Instead, stacks 12 are “self-supporting” when the bottom bin in the stack rests on the warehouse floor.

[0034] Robot 200, as shown in FIG. 5, includes a communication interface to send and receive data between the robot and a remote computer, such as a Warehouse Management System (WMS), enabling the remote computer to control movement and operation of each of the robots about grid 26. Robot 200 includes a body 202 and a wheel assembly 204. In one embodiment, wheel assembly 204 may include a plurality of wheels, a motor, and one or more transmissions (belts or linkages) operably coupling each one of the wheels to the motor. The orientation of the wheels is controlled by the motor and the one or more transmissions. More specifically, the motor is coupled to each one of the wheels, via the one or more transmissions, such that rotation of the motor simultaneously pivots the orientation of each one of the wheels. In this regard, the w heels may be concurrently pivoted between a first orientation in which each of the wheels isaligned with the first set of rails 22a and a second orientation in which each of the wheels is aligned with the second set of rails 22b (e.g.. 90 degrees). A drive mechanism is associated with wheel assembly 204 to rotate the wheels and move body 202 along the rails 22 in which the wheels are positioned.

[0035] In an alternative embodiment, the wheel assembly 204 of robot 200 may be constructed with first and second sets of non-pivotable wheels, one or more displacement mechanisms for lifting and lowering the first and second sets of wheels, and a drive mechanism, as is known in US Pat. No. 9,682,822. Specifically, wheel assembly 204 may include a first set of non-pivotable wheels (consisting of a pair of wheels on the front of the robot and a pair of wheels on the back of the robot), a second set of non-pivotable wheels (consisting of a pair of a wheels on each lateral side of the robot), one or more displacement mechanisms for lifting and low ering the first set second set of wheels aw ay from and into engagement with their respective rails, and a drive mechanism to rotate the wheels along the rail to which the wheels are engaged.

[0036] The body 202 of robot 200 may also include a picking arm 206 equipped with an end effector 208 for picking and packing inventory items and / or one or more storage bin retrieval devices 210. Picking arm 206 is movable in at least three dimensions to allow end effector 208 to pick inventory items from bin 100 and to pack the picked inventory items into an order bin. End effector 208 may be a pneumatically actuated end effector such as a suction cup.

[0037] As shown in FIG. 5, robot 200 includes two storage bin retrieval devices 210: a first storage bin retrieval device attached to a front of body 202 and a second storage bin retrieval device attached to a back of the body. However, it is contemplated that robot 200 may include zero, one, two, three or four storage bin retrieval devices 210 and that the storage bin retrieval devices may be attached to the sides of body 202 in any arrangement.

[0038] Each storage bin retrieval device 210 may include a pair of support arms 212 and a grapple 214 designed to extract storage bins 100 from framework 14 and / or secure order bins to the body 202 of robot 200. Grapple 214 is suspended from support arms 212 by cables or a chain (not shown and collectively referred to hereinafter as “cables”) which are connected to a winding mechanism 216 such as a spool, hoist, or winch. The cables can thus be wound and unwound to adjust the height of grapple 214 with respect to the support arms in the z-direction.

[0039] Grapple 214 may include a three-sided grapple frame 218 and a bin securement device such as pivotable flaps 220. The three sides of grapple frame 218 may be formed by opposing grapple arms 222 and a connector 224. Grapple arms 222 and connector 224 collectively define an aperture. Each flap may be pivotable relative to a respective grapple arm 222 between a deployed condition in which the flap extends away from the grapple arm to which it isconnected and into the aperture, and an undeployed condition in which the flap lies substantially flush against the grapple arm or is otherwise disposed within the footprint of the grapple arm. Movement of flaps 220 between the undeployed and deployed condition may be controlled by an actuator disposed within grapple 214 and configured to convert an electrical signal carried through the cables to motion of the flaps. When flaps 220 are in the undeployed condition, the aperture is larger than storage bin 100, allowing grapple 214 to be lowered into gap 18. and around a stack 12 of the storage bins, before the flaps are deployed and brought into engagement with an engagement feature such as a rib on a side of the storage bin. In this manner, storage bin retrieval device 210 is arranged to extract one or more storage bins 100 in a single lift (e.g., the storage bin secured to grapple 214 and any storage bins stacked thereon).

[0040] As orders are received by a warehouse, the WMS will direct robot 200 to pick inventory items from storage bins 100 and pack the items into an order bin. After receiving pick and pack instructions from the WMS, robot 200 may secure an order bin to grapple 214 and use wheel assembly 204 to navigate to a desired location on grid 26. For example, if the desired SKU is housed in a storage bin 20 located at the top of a stack 12, wheel assembly 204 may drive along rails 22 to position the grapple 214 securing the order bin above a grid space located adjacent to the grid space within which the item is located. Once in position, end effector 208 (e.g., suction cup) may be positioned within the storage bin to grasp the item. After the item has been grasped, picking arm 206 may be moved toward the order the container to pack the item.

[0041] On the other hand, if the desired item is housed within a storage bin 100 upon which other storage bins are stacked, the storage bin housing the desired item (e.g., the “target bin”) must first be extracted. To extract the target bin, robot 200 moves along rails 22 to position storage bin retrieval device 210 over the stack 12 housing the target bin. Grapple 214 may then be lowered into gap 18 and around stack 12 until the grapple is positioned around the storage bin nested within the target bin. With grapple 214 in position, flaps 220 may be deployed and brought into engagement with a rib, or another engagement feature, on a side of the storage bin to secure the storage bin to the grapple. With storage bin 100 secured to grapple 214, the winding mechanism may be wound to retract the grapple and to lift the storage bin and any storage bins located on top of that storage bin. The body 202 of robot 200 may then be moved to another location and each of the storage bins secured by grapple 214 may be temporarily placed on top of another stack 12. The storage bin retrieval device 210 may then be used to extract the target bin. With the extracted target bin secured to grapple 214, the picking arm 206 can pick the item from the target bin and pack the picked item into the order bin. The target bin and the storage bins that were temporarily displaced may then be returned to stack 12 in theiroriginal order. It will be appreciated that other robots 200 operating on grid 26 may assist in extracting the '’non-targel bins” (e.g., the bins stacked on top of the “target bin”), the “target bin,” or picking and packing the inventory item. Put differently, a single robot 200 need not perform each task necessary to pick and pack an item. That is, robots 200 operating on grid 26 may be assigned tasks from the WMS and work in conjunction with one another to fulfill one or more orders and increase overall fulfilment efficiency.

[0042] This process may be repeated until robot 200 has packed all the items relating to a particular order into the order bin. Robot 200 may then carry the completed order bin to another area of storage structure 10 or transfer the order bin out of the storage structure for further processing, for example, to an auto-packing machine, an auto-sealing machine, or another staging area.

[0043] To assemble framework 14, a worker must first survey the warehouse floor to ensure that it is substantially flat. It will be appreciated that if the floor within a grid-cell 27 is not level, the unlevel floor 12 may cause stacks 12 to tilt, which can hinder the vertical extension and retraction of the grapple 214. Moreover, if the tilt is severe enough, stacks 12 may topple. Conventionally, if the floor is not level, a new concrete floor must first be poured to level its surface. After the floor has been leveled, a worker may then determine the location at which each pillar 16 should be fixed. This determination is typically performed by conducting a series of measurements and marking a “grid” on the warehouse floor, securing a stabilization foot 28 (FIG. 4) at each marked location, and fastening a vertical member to each stabilization foot. Alternatively, pillar 16 may be secured directly to the warehouse floor at the determined location.

[0044] FIGS. 6 and 7 illustrate a leveling device 300 in accordance with an embodiment of the present disclosure. Leveling device 300 is designed to measure or analyze the inclination and / or deformation within a single grid-cell 27 so that the gnd-cell can be leveled with shims to create a flat surface, thereby removing the need to pour new and expensive concrete floors. As used herein, the term “flat surface” refers to a surface that is generally level, such that all points of bin 100 that sit on the surface are substantially co-planar. Leveling device 300 may include a frame 302. a level 304, a plurality of adjustable leveling posts 306, and a plurality of height indicator displays 308.

[0045] Frame 302 includes a lower surface 310, an upper surface 312, and a plurality' of vertices 314 (or “comers”) defining a convex hull polygon. The convex hull polygon of frame 302 is preferably designed to overlap a geometric center of rectangular grid-cell 27. For example, as shown in FIG. 6, frame 302 may have four vertices 314, each of which is designedto sit within a respective comer of grid-cell 27. The four vertices 314 may be rounded and designed to sit within a cutout of stabilizing foot 28.

[0046] Level 304 may be attached to a geometric center of frame 302 or at any other location. In one example, level 304 is a dual-axis inclinometer provided with a digital indicator 316 for measuring and simultaneously displaying the inclination or deformation of frame 302 in both the horizontal (x-axis) and vertical (y-axis) planes. It will be understood, however, that level 304 may be any device configured to measure the inclination or orientation of a surface, including but not limited to, an inertial measurement unit (IMU), an accelerometer, a gyroscope, a magnetometer, a horizon sensor, a laser, or an optical or ultrasonic sensor. Moreover, level 304 may have a digital, analog, or physical (e.g., bubble level) indicator for displaying the measurement.

[0047] As shown in FIG. 7, adjustable leveling post 306 may include a shaft 318 that is operatively secured to frame 302 via a thread, a gear, or any other connection. A base 320 designed to contact a ground surface may be coupled to a distal end of shaft 318, for example, at a spherical joint. In this manner, shaft 318 is movable in a downward vertical direction (z-axis) to move base 320 toward the warehouse floor and is retractable in an upward direction to move the base away from the warehouse floor. The movement of adjustable post 306 may be actuated automatically, via any active or passive mechanism, or actuated manually by a dial or knob 322. For example, to extend the base 320 of post 306 tow ard and into engagement with the warehouse floor, a worker may rotate knob 322 in a clockwise direction, and to retract the base, the worker may rotate the knob 322 in a counterclockwise direction. When a worker rotates knob 322 in a clockwise direction, the base 320 will move further underneath frame 302 and into engagement with the warehouse floor. After base 320 engages the warehouse floor, additional downward movement of base 320 will lift the side of frame 302 adjacent to adjustable leveling post 306 aw ay from the warehouse floor. Conversely, when a worker rotates knob 322 in a counterclockwise direction, the base 320 of leveling post 306 will retract towards and into frame 302, thereby lowering the side of frame 302 adjacent that adjustable leveling post toward the warehouse floor.

[0048] As shown in FIG. 6. leveling device 300 may include three adjustable leveling posts 306 to level frame 302. In one example, two of the adjustable leveling posts 306 are provided along a first midline of level 304 (e.g., x-axis or y-axis), and the third adjustable leveling post 306 is provided along a second midline of the level and arranged perpendicular to the first midline. Locating adjustable leveling posts 306 along the midlines of level 304, as described, affords the leveling posts with greater control in adjusting the inclination offrame 302 about its x-axis and the y-axis and increases the accuracy of the level. Nevertheless, leveling device 300 may have two adjustable leveling posts 306 or four or more adjustable leveling posts.

[0049] The height indicator displays 308 of leveling device 300 may be located at the vertices 314 of frame 302. In one example, each height indicator display 308 may be formed as a back-plunger digital dial indicator. The back-plunger digital dial indicator may include a spring-loaded back-plunger 324 having a distal tip 326 that extends underneath the lower surface 310 of frame 302, and an indicator display 328 that indicates the distance that the back-plunger is extended from the frame and displays this information upwardly towards a worker.

[0050] When gravitational forces act on frame 302 and push the comers of the frame into contact with the warehouse floor, the distal tip 326 of the spring-loaded back-plunger 324 will retract to sit at the plane of the lower surface 310 of the frame. Conversely, if the comers 314 of frame 302 are elevated off of the warehouse floor, the distal tip 326 of back-plunger 324 will extend into contact with the warehouse floor and the indicator display 328 will display the distance the distal tip 326 of the back-plunger extends from the lower surface 310 of frame 302. The displayed distance corresponds to a height of the deformation at that comer. Other height indicators such as inertial measurement units (IMU), accelerometers, gyroscopes, magnetometers, horizon sensors, lasers, optical or ultrasonic sensors, with digital, analog, or physical displays, may alternatively be utilized to determine a deformation of the floor. While FIGS. 6 and 7 illustrated the height indicator displays 308 as being attached to frame 302, the indicator display 328, may be remote (e.g., spaced) from frame 302. For example, indicator display 328 may be an app accessible and viewable via a computer on the workers cell phone. The display may also include the height measure and / or other calculations, data, sensor information or any other information related to the task of floor leveling.

[0051] Leveling device 300 may also include a zeroing block 332 to calibrate spring-loaded back-plunger to zero when the distal tip 326 is aligned with a plane of the lower surface 310 of frame 302. The frame 302 of leveling device 300 may also include a handle 334 to assist a worker in lifting and carrying the leveling device between grid-cells 27.

[0052] Prior to assembling framework 14. leveling device 300 may be utilized to level a warehouse floor as follows. After stabilizing feet 28 have been secured to the warehouse floor, a worker may place the lower surface 310 of frame 302 against the warehouse floor such that the four comers 314 of leveling device 300 abut the cutouts of the stabilizing feet defining a single grid-cell. Next, the worker may rotate the knobs 322 of adjustable posts 306 in a clockwise or counterclockwise direction to thread the bases 320 of the adjustable posts towardor away from the warehouse floor until the dual-axis inclinometer level indicates that the frame 302 is level (e.g.. horizontal or perpendicular to gravitational forces) in both the x-direction and the y-direction. When frame 302 is level, the spring-loaded back-plungers located at each comer 314 of the frame will extend a certain distance from the lower surface of the frame. The distance the distal tip 326 of back-plunger 324 extends from the lower surface 310 of the frame will correspond to the height of the deformation at that location, and this determination will be displayed by indicator display 328.

[0053] Using this information, a worker may secure one or more shims to the warehouse floor to level the grid-cell 27. For example, a first indicator display 328 may determine that a first comer 314 of frame 302 is elevated 2 mm off the floor, a second comer of the frame is elevated 2.5 mm off the floor, and third and fourth comers are flush with the ground. With this information, the worker may gather two shims having a thickness of 1 mm (and a sum of 2 mm) and secure them adjacent to the cutout of stabilizing foot 28 provided at the first comer. Similarly, the worker may gather two shims having a thickness of 1 mm and one shim having a thickness of 0.5 mm (and a sum of 2.5 mm) and secure them adjacent to the cutout of stabilizing foot 28 provided at the second comer, thereby leveling the grid-cell 27.

[0054] After the grid cell has been leveled, leveling device 300 may be again placed within the grid-cell to verify that the floor is flat. Upon verification, the worker may then grab handle 334 and lift leveling device to repeat the same process in each grid-cell 27. After the floor of each grid-cell has been leveled, the workers may then assemble framework 14. It other examples, leveling device 300 may be used to level the floor before stabilizing foot 28 has been secured to the floor and, in some instances, framework 14 may be assembled without stabilizing foot.

[0055] Leveling device 300 thus assists workers in leveling the floor inside of a grid-cell to securely level and stabilize stacks 12 within framework 14. In this manner, leveling device 300 avoids the need for pouring and leveling an expensive new concrete floor. It will be appreciated that leveling device 300 may be utilized to level the floor of warehouses deploying other gridbased storage structures, including grid-based storage structures in which the framework is designed to abut and supports the stacks, because a flatter warehouse floor would improve the alignment of those stacks and reduce stress placed on the framework of such systems.

[0056] Although the disclosure herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that otherarrangements may be devised without departing from the spirit and scope of the present disclosure as defined by the appended claims.

Claims

CLAIMS1. A leveling device, comprising:a frame having a lower surface and at least three vertices defining a plane, the frame being sized and arranged to sit on a floor and within an area corresponding to a single grid-cell of a grid-based storage structure;a level coupled to the frame; anda plurality of adjustable leveling posts coupled to the frame, each one of the plurality of adjustable leveling posts being movable in a vertical direction toward and away from the floor.

2. The leveling device of claim 1 , wherein the level is a dual-axis digital inclinometer.

3. The leveling device of claim 1, wherein the plurality of adjustable leveling posts includes a first adjustable leveling post, a second adjustable leveling post, and a third adjustable leveling post.

4. The leveling device of claim 3, wherein the first adjustable leveling post and the second adjustable leveling post are located along a first midline of the level.

5. The leveling device of claim 4, wherein the third adjustable leveling post is located along a second midline of the level, the second midline being arranged perpendicular to the first midline.

6. The leveling device of claim 1, further comprising a plurality of height indicator displays.

7. The leveling device of claim 6, wherein the plurality of height indicator displays is coupled to the frame, each height indicator display being arranged to display a distance between the floor and the low er surface of the frame at which that height indicator display is located.

8. The leveling device of claim 6, wherein each one of the plurality of height indicator displays comprises a back plunger dial indicator.

9. The leveling device of claim 8, further comprising a zeroing block configured to zero the plurality of back plunger dial indicators.

10. The leveling device of claim 6, wherein at least one of the plurality of height indicator displays is oriented in an upward direction.

11. The leveling device of claim 1, further comprising a handle.

12. The leveling device of claim 1, wherein the at least three vertices define a convex hull polygon configured to contain a geometric center point of the single grid-cell.

13. The leveling device of claim 1, wherein each one of the plurality of adjustable leveling posts includes a rotatable knob to move the post in the vertical direction.

14. A leveling device, comprising:a frame having a lower surface, an upper surface, and a plurality of comers, the frame being sized and arranged to sit on a floor within an area corresponding to a single grid-cell of a grid-based storage structure;a dual-axis level coupled to the frame;a first adjustable leveling post and a second adjustable leveling post provided along a first midline of the dual-axis level, the first and second adjustable leveling posts being arranged to move in a vertical direction towards and away from the floor;a third adjustable leveling post provided along a second midline of the dual-axis level, the second midline extending perpendicular to the first midline, the third adjustable leveling post being arranged to move in the vertical direction towards and away from the ground; and a plurality of height indicator displays, each height indicator display being arranged to display a distance between the lower surface of the frame and the ground located directly underneath that respective height indicator display.

15. A method of leveling a floor, comprising:placing a lower surface of a frame including a level on the floor such that each comer of the frame is within an area corresponding to a single grid-cell of a grid-based storage structure; andan adjusting step, comprising adjusting a first adjustable leveling post, adjusting a second adjustable leveling post, and / or adjusting a third adjustable leveling post in a vertical direction until the frame is substantially level in a horizontal direction.

16. The method of claim 15, wherein the adjusting step, comprises:rotating the first adjustable leveling post, the second adjustable leveling post, and the third adjustable leveling post.

17. The method of claim 15, further comprising:reading from a first height indicator display, a first distance between the lower surface of the frame and the floor located directly underneath the first height indicator display;reading from a second height indicator display, a second distance between the lower surface of the frame and the floor located directly underneath the second height indicator display; andreading from a third height indicator display, a third distance between the lower surface of the frame and the floor located directly underneath the third height indicator display.

18. The method of claim 17, further comprising:gathering one a more first shims, a first summation of which is equal to the first distance;gathering one a more second shims, a second summation of which is equal to the second distance; and / orgathering one a more third shims, a third summation of which is equal to the third distance.

19. The method of claim 18, further comprising:removing the frame from the area; andsecuring the one or more first shims, the one or more second shims, and / or the one or more third shims to the floor.

20. The method of claim 19. further comprising:placing the comers of the frame on at least one of the one or more first shims, the one or more second shims, or the at least one of the third shims; andverifying a levelness of the area.

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