Patent Application
20240217740
The present invention relates to a container handler for handling a storage container in a column of a frame structure of an automated storage and retrieval system. The present invention also relates to a container handling vehicle for handling a storage container in an automated storage and retrieval system. The present invention also relates to a method for handling a storage container in a column of a frame structure of an automated storage and retrieval system.
The framework structure 100 comprises upright members 102 and a storage volume comprising storage columns 105 arranged in rows between the upright members 102. In these storage columns 105 storage containers 106, also known as bins, are stacked one on top of one another to form stacks 107. The members 102 may typically be made of metal, e.g. extruded aluminum profiles.
The framework structure 100 of the automated storage and retrieval system 1 comprises a rail system 108 arranged across the top of framework structure 100, on which rail system 108 a plurality of container handling vehicles 201,301,401 may be operated to raise storage containers 106 from, and lower storage containers 106 into, the storage columns 105, and also to transport the storage containers 106 above the storage columns 105. The rail system 108 comprises a first set of parallel rails 110 arranged to guide movement of the container handling vehicles 201,301,401 in a first direction X across the top of the frame structure 100, and a second set of parallel rails 111 arranged perpendicular to the first set of rails 110 to guide movement of the container handling vehicles 201,301,401 in a second direction Y which is perpendicular to the first direction X. Containers 106 stored in the columns 105 are accessed by the container handling vehicles 201,301,401 through access openings 112 in the rail system 108. The container handling vehicles 201,301,401 can move laterally above the storage columns 105, i.e. in a plane which is parallel to the horizontal X-Y plane.
The upright members 102 of the framework structure 100 may be used to guide the storage containers during raising of the containers out from and lowering of the containers into the columns 105. The stacks 107 of containers 106 are typically self-supportive.
Each prior art container handling vehicle 201,301,401 comprises a vehicle body 201a, 301a,401a and first and second sets of wheels 201b, 301b,201c, 301c, 401b, 401c which enable the lateral movement of the container handling vehicles 201,301,401 in the X direction and in the Y direction, respectively. In
Each prior art container handling vehicle 201,301,401 also comprises a lifting device for vertical transportation of storage containers 106, e.g. raising a storage container 106 from, and lowering a storage container 106 into, a storage column 105. The lifting device comprises one or more gripping/engaging devices which are adapted to engage a storage container 106, and which gripping/engaging devices can be lowered from the vehicle 201,301,401 so that the position of the gripping/engaging devices with respect to the vehicle 201,301,401 can be adjusted in a third direction Z which is orthogonal the first direction X and the second direction Y. Parts of the gripping device of the container handling vehicles 301,401 are shown in
Conventionally, and also for the purpose of this application, Z=1 identifies the uppermost layer available for storage containers, i.e. the layer immediately below the rail system 108, Z=2 the second layer below the rail system 108, Z=3 the third layer etc. In the exemplary prior art disclosed in
The storage volume of the framework structure 100 has often been referred to as a grid 104, where the possible storage positions within this grid are referred to as storage cells. Each storage column may be identified by a position in an X- and Y-direction, while each storage cell may be identified by a container number in the X-, Y- and Z-direction.
Each prior art container handling vehicle 201,301,401 comprises a storage compartment or space for receiving and stowing a storage container 106 when transporting the storage container 106 across the rail system 108. The storage space may comprise a cavity arranged internally within the vehicle body 201a as shown in
The cavity container handling vehicles 201 shown in
Alternatively, the cavity container handling vehicles 401 may have a footprint which is larger than the lateral area defined by a storage column 105 as shown in
The rail system 108 typically comprises rails with grooves in which the wheels of the vehicles run. Alternatively, the rails may comprise upwardly protruding elements, where the wheels of the vehicles comprise flanges to prevent derailing. These grooves and upwardly protruding elements are collectively known as tracks. Each rail may comprise one track, or each rail may comprise two parallel tracks; or the rail system may comprise rails with one track in one direction and rails with two parallel tracks in the other direction.
WO2018/146304A1, the contents of which are incorporated herein by reference, illustrates a typical configuration of rail system 108 comprising rails and parallel tracks in both X and Y directions.
In the framework structure 100, a majority of the columns 105 are storage columns 105, i.e. columns 105 where storage containers 106 are stored in stacks 107.
However, some columns 105 may have other purposes. In
In
The access station may typically be a picking or a stocking station where product items are removed from or positioned into the storage containers 106. In a picking or a stocking station, the storage containers 106 are normally not removed from the automated storage and retrieval system 1, but are returned into the framework structure 100 again once accessed. A port can also be used for transferring storage containers to another storage facility (eg to another framework structure or to another automated storage and retrieval system), to a transport vehicle (e g a train or a lorry), or to a production facility.
A conveyor system comprising conveyors is normally employed to transport the storage containers between the port columns 119,120 and the access station.
If the port columns 119, 120 and the access station are located at different levels, the conveyor system may comprise a lift device with a vertical component for transporting the storage containers 106 vertically between the port column 119,120 and the access station.
The conveyor system may be arranged to transfer storage containers 106 between different framework structures, e.g. as is described in WO2014/075937A1, the contents of which are incorporated herein by reference.
When a storage container 106 stored in one of the columns 105 disclosed in
When a storage container 106 is to be stored in one of the columns 105, one of the container handling vehicles 201,301,401 is instructed to pick up the storage container 106 from the pick-up port column 120 and transport it to a location above the storage column 105 where it is to be stored. After any storage containers 106 positioned at or above the target position within the stack 107 have been removed, the container handling vehicle 201,301,401 positions the storage container 106 at the desired position. The removed storage containers 106 may then be lowered back into the storage column 105, or relocated to other storage columns 105.
For monitoring and controlling the automated storage and retrieval system 1, e.g. monitoring and controlling the location of respective storage containers 106 within the framework structure 100, the content of each storage container 106; and the movement of the container handling vehicles 201,301,401 so that a desired storage container 106 can be delivered to the desired location at the desired time without the container handling vehicles 201,301,401 colliding with each other, the automated storage and retrieval system 1 comprises a control system 500 which typically is computerized and which typically comprises a database for keeping track of the storage containers 106.
In
WO 2020/207777 describes a container-handling vehicle for picking up storage containers from a three-dimensional grid of an underlying storage system, comprising a vehicle body and at least one lifting device for lifting a storage container from the grid. The lifting frame comprises gripper elements for releasable connection to a storage container. The lifting frame further comprises a first rechargeable power supply for supplying energy to the gripper elements.
WO 2019/179856 describes an automated storage and retrieval system with a container handling vehicle comprising a lifting device with a lifting frame connectable to a storage container, wherein the vehicle comprises at least one reader, and wherein the system further comprises a storage container with at least one label, the at least one label comprises storage container information, and wherein the at least one reader is configured to read the at least one label such as to identify the storage container.
One object of the present invention is to provide an improved container handler of a container handling vehicle.
The present invention relates to a container handler for handling a storage container in a column of a frame structure of an automated storage and retrieval system, wherein the container handler comprises:
As used herein, the term “handling” refers to the actions of:
It should be noted that the term “position of the lifting frame relative to the storage container” may refer to the distance between the lifting frame and the storage container, speed or acceleration.
In one aspect, the first sensor is a non-contact sensor.
Accordingly, the first sensor is not in physical contact with the storage container. The mechanical wear on the sensor is therefore considerably reduced when compared to the prior art electromechanical sensor discussed above.
In one aspect, the first sensor is a capacitive sensor, an ultra-sonic sensor or an optical sensor.
In one aspect, the optical sensor is an optical sensor with light-emitting properties. It should be noted that the term “light” includes visible light, infrared light and ultraviolet light. As it is considered to be little or no light present in the storage columns of the storage system, in particular when the storage container of interest is stacked far below the top of the frame structure, the capacitive sensor, the ultra-sonic sensor or the optical sensor with light-emitting properties may be advantageous.
In one aspect, the container handler comprises a control system provided in communication with the first sensor; wherein the control system is controlling the vertical movement of the lifting frame and/or is controlling the gripper element based on a signal received from the first sensor.
In one aspect, the control system is provided in communication with a control system of the storage system.
In one aspect, the first sensor is provided at a vertical distance below the lifting frame or is extending along a vertical distance below the lifting frame.
The vertical distance is here defined as the distance from a lower contact surface of the lifting frame, wherein the lower contact surface is in physical contact with the storage container during the retrieving, inserting and holding action.
In one aspect, the distance between the first sensor and the lifting frame is 0.1-10 cm, preferably 2-5 cm.
In one aspect, the first guide pin comprises a further sensor for sensing the position of the storage container relative to the lifting frame, wherein the further sensor is provided at a further distance below the first sensor.
In one aspect, the first sensor is provided in the end of the first guide pin.
In one aspect, the container handler comprises four first guide pins protruding downwardly from the lifting frame for guiding the lifting frame vertically within the column of the frame structure relative to the storage container; wherein at least two of the first guide pins comprises first sensors for sensing the position of the lifting frame relative to the storage container.
In one aspect, one first sensor in one first guide pin may be provided at one distance from the lifting frame, while another first sensor in another guide pin may be provided at a different distance of the lifting frame.
In one aspect, the control system is configured to decelerate the lowering of the lifting frame down towards the storage container based on the signal received from the first sensor.
The prior art electromechanical sensor only gives the control system a confirmation signal confirming that physical contact between the lifting frame and the storage container has been achieved. Here, the control system is configured to reduce the speed of the vertical movement of the lifting frame towards the storage container based on the position, i.e. depth, of the storage container in the framework structure. This position is typically communicated to the container handling vehicle from the control system of the storage system. To avoid that the lifting frame crashing into the storage container, the speed of the lowering of the lifting frame is reduced when the lifting frame approaches the storage container.
Due to the sensor being located at distance from the lifting frame, the control system is able to predict more accurately the remaining vertical movement for the lifting frame until physical contact between the lifting frame and the storage container is achieved. This also allows the lifting frame to be lowered faster up to the point of deceleration. Hence, the safety margin for decelerating the speed of lowering of the lifting frame can be reduced, and a more efficient container handler is achieved. In addition, or alternatively, the speed of the vertical movement of the lifting frame can be increased for the first part of the decent, which will also increase efficiency.
In one aspect, the control system is configured to start the movement of the gripper before the lifting frame is in physical contact with the storage container based on the signal received from the first sensor.
In one aspect, the container handler comprises a top structure and a lifter for moving the lifting frame vertically relative to the top structure.
In one aspect, the top structure is a part of a container handling vehicle. Here, control system may be a vehicle control system.
In one aspect, the top structure is a part of a container lift. Here, the control system may be a lift control system.
In one aspect, the container handler comprises:
In one aspect, the first guide pin and the second guide pin are provided as one body secured to the lifting frame.
In one aspect, the second sensor is a non-contact sensor. In one aspect, also the second sensor is a capacitive sensor, an ultra-sonic sensor, an optical sensor and/or an optical sensor with light-emitting properties. Preferably, the first sensor and the second sensor are of the same type.
In one aspect, the control system is controlling the vertical movement of the lifting frame based on the signal received from the second sensor.
In one aspect, the second sensor is provided at a distance above the lifting frame or is extending along a distance above the lifting frame.
In one aspect, the top structure is a part of a container lift. In one aspect, the top structure is a part of a container handling vehicle.
In one aspect, the control system is configured to decelerate the elevation of the lifting frame up towards the top structure based on the signal received the second sensor.
In one aspect, the first sensor is directed towards a central axis of the lifting frame.
In one aspect, the lifting frame is adapted to be received at least partially within the top structure, wherein the second sensor is directed away from a central axis of the lifting frame.
In one aspect, the electric motor is connected to the lifting frame by means of bands. Alternatively, the electric motor is connected to the lifting frame by means of wires etc.
In one aspect, the lifting frame is a rectangular planar frame, preferably a plate-structure.
In one aspect, the lifting frame may comprise a central opening, allowing product items to be inserted into and retrieved from the storage container when held by the container handler.
The present invention also relates to a container handling vehicle for handling a storage container in an automated storage and retrieval system, wherein the container handling vehicle comprises:
The present invention also relates to a method for handling a storage container in a column of a frame structure of an automated storage and retrieval system, wherein the method comprises the following steps:
In one aspect, the method is controlling the vertical movement of the lifting frame in the immediate proximity of the storage container based on a signal received from the first sensor.
In one aspect, the method further comprises the step of:
In one aspect, the method further comprises the steps of:
In one aspect, the method is controlling the vertical movement of the lifting frame in the immediate proximity of the top structure based on a signal received from the second sensor.
Following drawings are appended to facilitate the understanding of the invention. The drawings show embodiments of the invention, which will now be described by way of example only, where:
In the following, embodiments of the invention will be discussed in more detail with reference to the appended drawings. It should be understood, however, that the drawings are not intended to limit the invention to the subject-matter depicted in the drawings.
Initially, it is referred to
The container handler 10 further comprise a lifting frame 20 vertically movable relative to the top structure 11 by means of the lifter 12 and bands 14 reeled onto and reeled out from the band reel.
The top structure 11 may be a part of a container handling vehicle, for example one of the container vehicles 201, 301, 401. The top structure 11 may also be a part of a container lift, for example a container lift used to lift storage containers down to or up from a port, an access station etc. The container lift may use one dedicated column of the framework structure 100 to supply storage containers to and/or retrieve storage containers from this access station.
The container handler 10 comprises four first guide pins 30 and four second guide pins 50. The first guide pins 30 are located in the respective corners of the lifting frame 20 and protrude downwardly from the lifting frame 20. The second guide pins 50 are also located in the respective corners of the lifting frame 20, but they protrude upwardly from the lifting frame 20.
The first guide pins 30 and second guide pins 50 are used for guiding the lifting frame 20 relative to the column 105 in the framework structure 100, to ensure that the lifting frame is correctly positioned relative to the horizontal members of the framework structure 100 and relative to the storage container 106. In addition, the first guide pins 30 are used for guiding the lifting frame 20 relative to the storage container 106. In
The container handler 10 further comprises a gripper element 40 protruding downwardly from the lifting frame 20 for gripping the storage container 106. The gripper element 40 may be of a prior art type, and will not be described further in detail herein. The gripper element 10 has two states—a gripping state, in which the storage container will be lifted together with the lifting frame, and a releasing state in which the storage container will not be lifted together with the lifting frame.
The container handler 10 further comprises a control system CS for controlling the lifter 12 and the gripper element 40.
It is now referred to
It is now referred to
The above first sensor 35 and second sensor 55 are preferably non-contact sensors, and hence, the first sensor 35 is not in physical contact with the storage container and the second sensor 55 is not in contact with the top structure 11. The mechanical wear on the sensors is therefore considerably reduced when compared to the prior art electromechanical sensor.
The first sensor 35 and the second sensor 55 may be a capacitive sensor, an ultra-sonic sensor or an optical sensor, for example an optical sensor with light-emitting properties.
In addition to reduced mechanical wear, another advantage with the first sensor 35 is that the exact position of the storage container 106 may be sensed before the lifting frame 20 comes into physical contact with the storage container. Similarly, by means of the second sensor 55, the exact position of the top structure 11 may be sensed before the lifting frame 20 comes into physical contact with the top structure 11.
The control system CS is provided in communication with the first sensor 35 and the second sensor 55. The control system CS is configured to control the vertical movement of the lifting frame 20 based on the signals from the first sensor 35 and the second sensor 55. It should be noted that the control system CS is also in communication with the central control system 500 of the automated storage and retrieval system 1.
It should be noted that the output signal from the first sensor 35 and the second sensor 55 may be of different types. In one embodiment, the output signal may be a Boolean signal, i.e. either true or false, where false may represent a state where no storage container or top structure has been detected and where true may represent a state where a storage container or top structure has been detected. In a second embodiment, the output signal may be a continuous or discrete parameter indicating gradually how far the lifting frame 20 is from the storage container or the top structure.
Initially, it should be noted that the efficiency of the automated storage and retrieval system 1 is dependent on many factors. One such factor is the time used to retrieve storage containers from the storage columns, the time used to insert storage containers into the storage columns, the time used to supply storage containers to access points and the time used to retrieve storage containers from the access points. Therefore, it is advantageous that the lifting frame moves as fast as possible. In prior art, the position of the storage container is known. Therefore, also the depth (z-level) of the storage container is known. During retrieval, the lifting frame 20 is therefore lowered towards the storage container at maximum speed until the lifting frame approaches the expected depth of the storage container and deceleration starts to avoid that the lifting frame crashes into the storage container.
Due to the first sensor 35 being located at distance D35 from the lifting frame 20, the control system CS is able to predict more accurately the remaining vertical movement for the lifting frame 20 until physical contact between the lifting frame 20 and the storage container 106 is achieved. This also allows the lifting frame 20 to be lowered faster up to the point of deceleration. Hence, the safety margin for decelerating the speed of lowering of the lifting frame can be reduced, and a more efficient container handler 10 is achieved. In addition, or alternatively, the speed of the vertical movement of the lifting frame 20 can be increased for the first part of the decent, which will also increase efficiency.
In addition, the control system CS may be configured to start the movement of the gripper 40 before the lifting frame 20 is in physical contact with the storage container 106 based on the signal received from the first sensor 35.
Due to the second sensor 55 being located at distance D55 from the lifting frame 20, the control system CS is able to predict more accurately the remaining vertical movement for the lifting frame 20 until physical contact between the lifting frame 20 and the top structure 11 is achieved. This also allows the lifting frame 20 to be elevated faster up to the point of deceleration. Hence, the safety margin for decelerating the speed of elevation of the lifting frame can be reduced, and a more efficient container handler 10 is achieved. In addition, or alternatively, the speed of the vertical movement of the lifting frame 20 can be increased for the first part of the elevation which will also increase efficiency.
Different embodiments of the invention will be described below. It should be noted that only differences with respect to the first embodiment above will be described in detail.
It is now referred to
It should be noted that the same type of sensor may be used for the upwardly protruding second guiding pins 50 in the embodiment shown in
It is now referred to
In an alternative embodiment, the reference number 35f in
In yet an alternative embodiment, in case the first sensor 35 and/or the second sensor 55 is a light sensor able to sense different colours or patterns, it may also be possible to provide the storage container and/or the top structure with different colours or a pattern, where each colour or parts of the pattern indicates a different height. This may increase accuracy of the measurements by using one sensor only.
The top structure 11 may comprise a receiving bore for receiving the upwardly protruding second guides. This may stabilize the lifting frame 50 and hence also the storage container lifted by the lifting frame relative to the top structure when the lifting frame is in the upper position.
In the preceding description, various aspects of the container handler have been described with reference to the illustrative embodiment. For purposes of explanation, specific numbers, systems and configurations were set forth in order to provide a thorough understanding of the system and its workings. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiment, as well as other embodiments of the system, which are apparent to persons skilled in the art to which the disclosed subject matter pertains, are deemed to lie within the scope of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 20210521 | Apr 2021 | NO | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/059819 | 4/13/2022 | WO |
