Patent Application
20160031687
The invention relates to an arrangement comprising a rail line, at least one racking row disposed alongside the rail line, a storage and retrieval unit which can be moved on the rail and a power supply and/or a power supply rail electrically connected to the rail line which is in contact with the storage and retrieval unit. The invention further relates to a method of operating said arrangement, specifically for operating a storage and retrieval unit which can be moved on a rail line and is supplied by a power supply and/or a power supply rail electrically connected to the rail line, by means of which at least one racking row disposed alongside the rail line can be accessed.
Such an arrangement and such a method are known in principle from the prior art. For example, said rail line is disposed in a racking aisle between two racking rows so that the storage and retrieval unit can service racking shelves to the left and right of the rail line, in other words deposit objects in the shelf or retrieve objects from it. Several racking rows and rail lines may naturally also be disposed one above the other to create a storage system with several levels. A vertical conveyor may be provided at the front end of the shelves, i.e. at the end of a rail line. A horizontal conveyor (e.g. conveyor belt or conveyor rollers) may also be provided at the end of a rail line or on the vertical conveyor as well as a picking station, for example.
Although such storage systems are usually operated on a fully automated basis via a central control computer, it is necessary for an operator to enter a storage aisle from time to time, for example to carry out maintenance work on the storage and retrieval unit, the rail line or on the shelf itself, and also to remove objects which have become jammed during handling by the storage and retrieval unit. Since the storage and retrieval units reach high speeds and are also relatively heavy, special safety precautions need to be taken to protect the operator when moving in the racking aisle and approaching the rail line in front of the storage and retrieval unit.
To this end, DE 39 15 681 A1 discloses an arrangement whereby a photoelectric sensor is used to detect when a person enters the racking aisle. This enables a horn to be sounded or a signal lamp or barrier to be activated.
US 2012/0185080 A1 also discloses gates or barriers to prevent a storage and retrieval unit from entering a secured area of the racking aisle.
DE 196 28 123 A1 also discloses a system for detecting a person in or in the vicinity of a racking aisle by means of photoelectric sensors, for example. In the event of a situation posing a risk, the storage and retrieval units are controlled so that they operate in a slow creeping motion or are even brought to a halt.
Other prior art documents addressing this subject are DE 39 19 167 C1 and DE 41 12 728 A1.
The disadvantage of the known methods is that more or less singular precautions are taken but these are not based on a concept whereby the storage and retrieval unit can be effectively prevented from moving in a situation of risk, even though a minimum power supply thereof is maintained.
Accordingly, it is an objective of the invention to propose an improved arrangement and an improved method of operating a storage and retrieval unit. In particular, the intention is to effectively prevent the storage and retrieval unit from moving in the event of a dangerous situation whilst nevertheless ensuring that it has a minimum power supply.
The objective is achieved by the invention on the basis of a method of the type outlined above, whereby the rail line/power supply rail is set to a risk mode voltage, the rectified value/effective value of which lies below a minimum rectified value/minimum effective value necessary to move the storage and retrieval unit but above zero, if a risk posed by the storage and retrieval unit is detected.
The objective of the invention is also achieved by means of a method of the type outlined above, whereby
In this instance too, the rectified value/effective value of the risk mode voltage may preferably lie below a minimum rectified value/minimum effective value necessary to move the storage and retrieval unit but above zero.
The objective of the invention is also achieved by means of an arrangement of the type outlined above comprising a drive control system configured to set the rail line/power supply rail to a risk mode voltage, the rectified value/effective value of which lies below a minimum rectified value/minimum effective value necessary to move the storage and retrieval unit but above zero, when a risk posed by the storage and retrieval unit is detected.
Finally, the objective of the invention is also achieved by means of an arrangement of the type outlined above, further comprising
As a result of the proposed features, it is possible to supply the storage and retrieval unit (also known as a shuttle in the case of a single-level rack servicing device) with electrical energy, even in the event of a risk, for example in order to keep important electronic components in operation without back-up capacitors or back-up batteries, even in the event of a risk. For example, this can be achieved by a communication module or a position encoder of the storage and retrieval unit so that normal operation can be resumed without problem following risk mode operation. Another advantage is that analyzing a fault and removing a fault on the supplied storage and retrieval unit is made easier. For example, error codes can be displayed on the storage and retrieval unit and setting of sensors is also made easier, for example, due to the fact that the power supply is maintained.
In spite of the fact that the power supply of the storage and retrieval unit is guaranteed even in the event of a risk, the implemented measures guarantee that a person present on the rail line is effectively protected. Especially if the rectified value/effective value of the risk mode voltage lies below a minimum rectified value/minimum effective value necessary to move the storage and retrieval unit, any movement of the storage and retrieval unit can be ruled out for physical reasons alone. In other words, too little power is forwarded to the traction motor of the storage and retrieval unit for the storage and retrieval unit to be able to move. Personnel protection is therefore particularly effective.
The “effective value” is calculated by squaring and then determining a mean value and the “rectified value” is obtained by rectification and then determining a mean value. In the case of unipolar voltages, the “rectified value” therefore simultaneously corresponds to the (arithmetic) “mean value”.
The term “move” in the context of the invention primarily refers to the movement of the entire storage and retrieval, unit, i.e. a travelling movement thereof on the rail line. However, “moving” can also refer to part areas of the storage and retrieval unit, for example to the extending and retracting movements and general movements of a lifting fork. Depending on the inertia of the moved unit and its driving power, different minimum rectified values/minimum effective values may be applied. It should also be noted that the drive need not necessarily be electrically operated and the electric power described above may be converted into another form, for example to pneumatic or hydraulic energy.
Other advantageous embodiments and features are defined in the dependent claims as well as the description of the drawings.
It is of advantage if the maximum value of the risk mode voltage in terms of amount lies below the minimum traction voltage. This offers even higher safety during operation of the storage and retrieval unit.
It is of advantage if the risk mode voltage is applied with the same polarity as the minimum traction voltage applied to the rail line/power supply rail. This means that special circuit features in the storage and retrieval unit can be dispensed with, such as the provision of a rectifier, for example. The motor controller can therefore be kept to a simple design.
However, it is also of advantage if the risk mode voltage is applied to the rail line/power supply rail with a polarity opposite the polarity of the minimum traction voltage. If the storage and retrieval unit is wired accordingly to prevent the risk mode voltage of opposite polarity from being forwarded to the motor, the risk mode voltage may be at any level. This means that in risk mode operation, components requiring a relatively high voltage can also be supplied, in particular a voltage which on average lies above the minimum traction voltage necessary to move the storage and retrieval unit. Electric power storage means (e.g. accumulators or capacitors) may optionally be provided in the storage and retrieval unit in order to bridge the time needed to reverse the polarity of the voltage.
It is of practical advantage if the risk mode voltage essentially has only a direct component, that is to say is essentially provided as direct voltage. This means that the drive control system can be kept particularly simple and robust. Outages and faults thereof can therefore be largely avoided.
It is also of practical advantage if the risk mode voltage essentially has only an alternating component. Especially if using a dc motor and a sufficiently high frequency of the risk mode voltage compared with the inertia of the storage and retrieval unit, a movement of the storage and retrieval unit can be prevented even without special circuit features in the storage and retrieval unit. This is because on average, the risk mode voltage in this instance does not have a direct component that would be necessary to move a dc motor.
It is also of practical advantage if the risk mode voltage has a direct component and an alternating component. This enables a part thereof to be used as a control signal. For example, the change signal contained in the risk mode voltage can be used as a control signal for the storage and retrieval unit. However, it would also be conceivable to use the direct component for this purpose.
In addition, it is also of advantage if said change signal is sinusoidal or in the form of a digital signal. A sinusoidal change signal can be coupled into the traction voltage particularly easily and coupled out of it. By way of example, a transformer or filter may be provided in the storage and retrieval unit for this purpose. With the aid of a digital signal, complex control commands can also be transmitted to the storage and retrieval unit. Furthermore, it is generally insensitive to interference. For example, the frequency hopping method or the spread spectrum method may be used for this purpose and control commands can be transmitted with a high degree of data security.
Finally, it is of advantage if an alternating voltage component in the storage and retrieval unit coupled out of the traction voltage (e.g. the entire alternating component or a specific frequency component thereof) is forwarded to the control coil of a relay and holds it in a switched state and the relay is configured to disconnect the traction voltage from the traction motor. In particular, the alternating component can be coupled out via a transformer and/or a filter and then rectified if necessary. Depending on whether the traction voltage applied to the storage and retrieval unit has an alternating component (in particular with a specific frequency) or not, the relay can be opened or closed and activation of the motor can be controlled in this manner. It is of particular advantage if this feature is used as an additional feature in conjunction with other safety measures.
At this stage, it should be pointed out that the different embodiments of the operating method proposed by the invention that are described here as well as the resultant advantages equally apply to the arrangement proposed by the invention and vice versa.
To provide a clearer understanding, the invention will be described in more detail below with reference to the appended drawings. Of these:
Firstly, it should be pointed out that the same parts described in the different embodiments are denoted by the same reference numbers and the same component names and the disclosures made throughout the description can be transposed in terms of meaning to same parts bearing the same reference numbers or same component names. Furthermore, the positions chosen for the purposes of the description, such as top, bottom, side, etc., relate to the drawing specifically being described and can be transposed in terms of meaning to a new position when another position is being described. Individual features or combinations of features from the different embodiments illustrated and described may be construed as independent inventive solutions or solutions proposed by the invention in their own right.
The arrangement illustrated in
During normal operation, the storage and retrieval unit 3 receives commands from a master controller, not illustrated, to pick up objects from a transfer station and deposit them in the shelving or to retrieve objects therefrom and take them to the transfer station. Transfer stations may be provided respectively at the ends of the rail line 1. A vertical conveyor device may also be provided there so that several rail lines 1 may be disposed one above the other, thereby forming a storage system with several levels. It would also be conceivable to provide a horizontal conveyor device (e.g. conveyor belts or conveyor rollers) respectively on the vertical conveyor device at the transfer station to enable the objects to be brought in and out accordingly. It would also be conceivable for a picking work station to be provided respectively on the vertical conveyor device at the transfer station.
During normal operation, the storage and retrieval unit 3 operates on a fully automated basis. In specific situations, however, it may be necessary for an operator to intervene, for example if objects become wedged, the storage and retrieval unit 3 is faulty or the conveyor flow is disrupted in some other way. Since the storage and retrieval unit 3 moves at a relatively high speed, the operator must be protected when walking in the racking aisle or by the rail line 1. To this end, the operator depresses the push-button switch 14, whereupon the storage and retrieval unit 3 is brought to a halt. In addition, the entrance to the racking aisle is also monitored by the photoelectric barrier 13. For additional protection, the door 11 is provided at the right-hand end of the racking aisle, which is monitored by means of the switch 12. This results in a protected zone 15. In addition, protective fencing may be provided around the shelves 2.
If a person is detected entering the racking aisle, be it from the left or right, the storage and retrieval unit 3 is brought to a halt automatically, i.e. without the push-button switch 14 having to be explicitly depressed for this purpose. In
The drive control system 70 then sets the rail line 1/power supply rail 6 to a risk mode voltage, the rectified value/effective value of which lies below a minimum rectified value/minimum effective value necessary to move the storage and retrieval unit 3 but above zero, if a risk posed by the storage and retrieval unit 3 is detected, i.e. if the push-button switch 14 is depressed or the photoelectric barrier 13 or switch 12 indicates that the racking aisle is being entered. In this manner, an electronic control system of the storage and retrieval unit 3, for example the drive control system, can advantageously continue to be supplied with power, although the storage and retrieval unit 3 is not able to move due to the low voltage. In this respect, the voltage level may be selected so that it lies below the starting voltage so that the stationary storage and retrieval unit 3 can no longer move off or it may even be below the traction voltage, in which case a moving storage and retrieval unit 3 is brought to a halt. For example, the voltage during normal operation may lie at less than 100V and in particular at 70V, 24V or 48V, whereas the risk mode voltage may be, for example, less than 24V and in particular 5V or 12V, which is usually sufficient for supplying electronic components. It would also be conceivable for only important circuits to be designed to run on risk mode voltage whilst other circuits, including the motor 5, are switched off. For example, it may be that position encoders and communication modules continue to operate without restriction even when only the risk mode voltage is applied to guarantee seamless resumption of normal operation following risk mode operation.
Due to the inertia of the storage and retrieval unit 3, it is usually sufficient if the rectified value/effective value of the risk mode voltage lies below a rectified value/effective value of the traction voltage necessary to move the storage and retrieval unit 3. For even greater safety, however, it may be that the maximum value of the risk mode voltage is at a level below the minimum traction voltage.
In the example illustrated in
In this connection,
Based on the combinations illustrated in
However, it would also be conceivable for the traction voltage to be a direct voltage during normal operation and the risk mode voltage essentially has only an alternating component, i.e. is an alternating voltage. Again in this case, the circuit 19 would be supplied with electrical energy in both situations, whereas the motor 5 is only supplied with electrical energy with every second half-wave of the alternating voltage. On average, the voltage therefore drops to a lower value. It would also be conceivable to connect the motor 5 directly to the voltage source 8, i.e. without the diode 18 connected in between, in which case it must necessarily be a direct voltage motor. Due to the fact that the risk mode voltage does not essentially have a direct component, the motor 5 will simply stop at a sufficiently high frequency of the risk mode voltage due to its inertia, whereas circuit 19 will continue to be supplied with electrical energy.
Finally, it would also be conceivable to integrate an additional fuse in the drive control system 72 in the path for the risk mode voltage, which is designed to operate with the current for supplying the storage and retrieval unit 3 in the event of a risk but not for the motor current of the motor 5. This will prevent the storage and retrieval unit 3 from being set in motion if the diode 18 breaks down and becomes conductive. If this situation were to arise, the above-mentioned fuse in the drive control system 72 would kick in and prevent any movement of the storage and retrieval unit 3.
Another possible way of making the racking aisle safe is as follows:
In this connection,
In the examples illustrated, the modulated sinusoidal signal has a constant frequency and a constant amplitude. Naturally, this is not necessarily the case. It would also be conceivable for the frequency and/or amplitude of the modulated sinusoidal signal to be variable, i.e. the sinusoidal signal is frequency- and/or amplitude-modulated. Furthermore, signals can also be generally superimposed on a unipolar or bipolar basis, i.e. starting from a fundamental voltage may have only one polarity or may have both.
These components contained in the supply voltage for the storage and retrieval unit 3 can then be used to bring the storage and retrieval unit 3 to a halt in the event of a risk.
Based on a first example, it is assumed that the traction voltage contains the predefined digital signal illustrated in
However, it would also be conceivable for the risk mode voltage to contain the predefined digital signal and the traction voltage does not contain this digital signal (case b). The risk mode voltage therefore has a direct component and an alternating component. In this case, the conditions outlined above are the reverse so that the switch 23 remains open as long as the decoder 22 is able to detect the agreed digital signal in the supply voltage.
Finally, it would also be conceivable for the traction voltage to contain a predefined first digital signal and the risk mode voltage to contain a predefined second, different digital signal. In this case, the switch 23 remains open as long as the decoder 22 is able to detect the agreed second digital signal in the supply voltage. If, on the other hand, the decoder 22 detects the first digital signal in the supply voltage, the switch 23 will be closed.
Naturally, for the safety system described above, it need not necessarily be that a digital signal is modulated and instead sinusoidal change signals may also be modulated (see
For the purpose of the invention, it is generally speaking not necessary for the change signal to be constantly modulated or constantly monitored during normal operation or in risk mode. It would also be conceivable for modulation and monitoring to be carried out on a periodic basis only.
The two-channel principle may also be applied as a means of increasing safety, whereby two or more mutually independent units are involved in transmitting a switch command to the switch 23. This being the case, the motor 5 will only be supplied with the traction voltage if all or at least the majority of these units come to the same decision (switch 23 off or on). In this respect, it is of particular advantage if the units are of different designs or made by different manufacturers. For example, instead of the single decoder 22 illustrated in
For example, the decoupler 24 could be provided in the form of a transformer and thus couples out the entire alternating component of the traction voltage and directs it via the optional rectifier 26 to the control coil of the relay 25. It would also be conceivable for the decoupler to be provided in the form of a filter, in which case only a specific frequency component is coupled out of the traction voltage. This is of particular advantage in case c), where both the traction voltage and the risk mode voltage contain an alternating component. If the relay 25 is provided as a closer, the filter 24 will be configured for the frequency of the alternating component contained in the traction voltage during normal operation. If, on the other hand, the relay 25 is provided as an opener, the filter 24 will be configured for the frequency of the alternating component contained in the risk mode voltage. Naturally, it would also be possible to use transformers and filters in combination.
Generally speaking, it would also be conceivable for the motor 5 to be switched away from the voltage applied to the storage and retrieval unit 3 below a specific voltage level, especially in the presence of risk mode voltage. The circuit structure illustrated in
The embodiments illustrated as examples represent possible variants of drive control systems 70 . . . 73 and motor controllers 100 . . . 103, and it should be pointed out at this stage that the invention is not specifically limited to the variants specifically illustrated, and these possible variations lie within the reach of the person skilled in this technical field given the disclosed technical teaching.
In particular, the illustrated variants may be used in any combination. For example, the variant illustrated in
For the same reason, it would also be conceivable to combine the variant illustrated in
It would naturally also be conceivable to combine all three of the variants illustrated in
Generally speaking, the embodiments are described with reference to a dc motor. This being the case, the traction voltage may have a direct component and optionally an alternating component. However, the invention may naturally also be used without restriction for ac motors and three-phase motors. For example, in this instance the risk mode voltage may be reduced compared with the traction voltage during normal operation or a change signal can be modulated on the traction voltage (see also
Furthermore, the storage and retrieval unit 3 is described in the examples as being able to move in only the horizontal direction. However, this is not necessarily the case. The storage and retrieval unit 3 may also move vertically, at an angle and horizontally and vertically. In the latter case, it is provided in the form of a horizontally displaceable lift with a lifting fork.
It should also be noted that the (mechanical) switches 17, 23 and 25 are illustrated in the drawings as being of the same type for reasons of easier understanding but these can be replaced by electronic switches. For example, instead of the switch 18 illustrated in
It should also be specifically pointed out that the illustrated controllers and bearing arrangements may in reality comprise more or fewer components than those illustrated and the drawings are but highly simplified representations.
For the sake of good order, finally, it should be noted that in order to provide a clearer understanding of their design, the drive control systems 70 . . . 73, motor controllers 100 . . . 103 and the arrangement in
The objective underlying the independent inventive solutions may be found in the description.
| Number | Date | Country | Kind |
|---|---|---|---|
| A 50211/2013 | Mar 2013 | AT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/AT2014/050073 | 3/25/2014 | WO | 00 |
