This invention relates to load handling systems, especially in a warehouse setting, even more specifically to unmanned warehouse shuttle with telescopic arms.
There is a large number of disclosures for various kinds of load handling systems in a warehouse setting. A general feature of the systems includes a shuttle device moving between the warehouse shelves and reaching to pick packages, or items from the shelf to transport the package or items to a destination. A problem that many of the disclosures address is either how to load more than one package onto the shuttle at the very same time, or how to enable picking packages of different sizes onto the shuttle.
U.S. Pat. No. 8,790,061 discloses a transferring shuttle for use in a three-dimensional automated warehouse. The shuttle comprises sliding rails that comprise multiple finger elements such that the system can load more than one package at the time on the system in between the finger elements.
U.S. Pat. No. 10,894,663 discloses an automated storage retrieval system where telescopic arm assemblies include movable pusher elements and linearly moving tabs on the arms so as to change a distance between the tab and a finger to fit items of different size on the system. The telescopic arm is constructed to have multiple layers of extending and retracting members sliding in series within each other via belt and pulley arrangement in each of the telescoping members.
U.S. Pat. No. 10,865,042 as well as U.S. Pat. No. 9,522,781 disclose a device for gripping a load, wherein the system has chassis elements that are moving in relation to each other so as to change the width between gripping arms that are attached to the chassis portions and that way adopt to loading items of different widths. The system includes locking mechanisms to lock the chassis elements to preferred distance from each other. Drive assemblies including a rotatable drum and a cable extend and retracts the telescopic arms.
Thus, there are solutions providing various kind of tabs which may be stationary or moving on the arms to pick more than one package or packages with different depth onto the shuttle and there are systems where the shuttle comprises a loading space the width of which can be adjusted to pick packages with different width onto the shuttle.
Despite the multitude of existing solutions, there is a need for a shuttle system having a stable structure and where the telescopic arms can reach deep into the shelves and pick packages that are not only of different depth but also of different width. Moreover, there is a need for a shuttle system where the arms can extend deep into the shelf without a need to use multiple layers in extending elements.
Accordingly, this disclosure provides solutions to a stable and reliable system capable of handling various sizes of packages and moving them fast and stably on the system. The system provides increased stability in that a solid platform with stationary side compartments is provided, and the telescopic arms are constructed in a way that the two extending parts move on top of each other rather than forming a layered structure. The width of the loading space and distance between the arms is adjustable with simple screw system. A unique extension system for the extendable arms is disclosed where two of the three parts of the arms are extending and providing an extension length that is more than twice the depth of the platform of the shuttle.
It is an object of this invention to provide an unmanned warehouse shuttle, configured to move along warehouse rails and retrieve and depose crates from and to the warehouse shelves, said shuttle comprising a platform having a width and a depth, and having at least four wheels underneath the platform configured to drive the shuttle along the warehouse rails; two stationary compartments on top of the platform on opposite edges of the platform in shuttle moving direction; two telescopic arms located in the inner side of the stationary compartments and leaving a loading space between the arms; the arms being configured to extend in synchrony to two directions perpendicular to the shuttle moving direction so as to reach toward the warehouse shelves; each telescopic arm comprising a first, a second, and a third part, each having a length equal to the depth of the platform, the first part being stationary, the second part being configured to extend almost half of its length over the platform's edge toward the warehouse shelves, and the third part being configured to move more than half of its length over a distal end of the second part, whereby each telescopic arm has an extension length that is more than twice the depth of the platform.
The telescopic arms of the shuttle are connected to each other with an attachment element, for example a screw from underneath of the platform such that a distance between the arms can be adjusted by turning the screw, thereby adjusting the width of the loading space in between the arms.
According to certain embodiments at each distal part of the third part there is a motor driven lever and optionally an optical sensor. According to certain embodiments the lever may be mechanical.
According to certain embodiments the shuttle has at least four rollers having a horizontal rotation axis attached on the platform above the wheels and the rollers are configured to roll along a vertical side of a warehouse rail and to hold a standard distance between the platform and the warehouse rail.
According to certain embodiments the extension of the telescopic arms of the shuttle is enabled by means of multiple pinions and toothed racks, wherein a motor driven pinion is attached in a middle of the first part and the pinion is assembled to be in contact with a toothed rack attached to the second part; a pinion assembly comprising two larger pinions and one smaller in between the larger ones is attached to the second part, the larger pinions are in contact with a rack of the third part, and the smaller pinion is in contact with a rack of the first part; while the pinions are configured to turn at same rate but due to their different sizes the rack of the third part moves more than the rack of the second part, and extension amount of the third part correlates to distance between axels and circumference of the smaller pinion and the larger one that is in contact with the rack of the third part.
According to certain embodiment the three pinions in the pinion assembly are in direct contact with each other, while according to another embodiment the three pinions in the pinion assembly are not in contact with each other, but each has its own pulley, and the pinions are connected with a toothed drive belt.
It is an object of the invention to provide a telescopic arm assembly for a warehouse shuttle, the assembly comprising two parallel telescopic arms assembled on a platform of the shuttle such that a loading space is between the arms; each arm comprising: a first part; a second part, and a third part each having an equal length; the first part being stationary, the second part being configured to extend almost half of its length over the platform's edge toward shelves of the warehouse, and the third part being configured to extend more than half of its length over a distal end of the second part, whereby each telescopic arm has an extension length that is more than twice the depth of the platform.
According to certain embodiments of the telescopic arm assembly, the extension of the telescopic arms is enabled by means of multiple pinions and toothed racks, wherein a motor driven pinion is attached in a middle of the first part and the pinion is assembled to be in contact with a toothed rack attached to the second part; a pinion assembly comprising two larger pinions and one smaller in between the larger pinions is attached to the second part, the two larger pinions are in contact with a rack of the third part, and the smaller pinion is in contact with a rack of the first part; while the pinions are configured to turn at same rate but due to their different sizes the rack of the third part moves more than the rack of the second part, and an extension amount of the third part correlates to distance between axels of the smaller pinion and the larger pinion that is in contact with the rack of the third part.
According to certain embodiments the three pinions in the pinion assembly are in contact with each other, while according to certain embodiment the three pinions in the pinion assembly are not in contact with each other, but each has its own pulley, and the pinions are connected with a toothed drive belt.
The shuttle of this disclosure comprises a platform (1), two stationary side compartments (1a), two telescopic arms (4) and a loading space (1b) in between of the side compartments to load a crate. The shuttle has an even number of wheels (2) such that half of the wheels are on one side and half of them on the other side of the platform. The wheels are preferably located on opposite sides of the side compartment. Preferably the shuttle has four wheels, two on each side as is shown in
The wheels are configured to move the shuttle along an aisle of a warehouse structure between the shelving structures on warehouse rail structures (24). The rail structures are preferably created by the shelving's most forward part that protrudes into the corridor between the shelving structure. The wheels are preferably made of polyurethane or similar wear resistant material.
In addition to the wheels, the shuttle has an even number of support rollers (3) such that two sides of the platform have an equal number of support rollers. In
In one embodiment, the shuttle has at least one wheel drive motor (7) within one side compartment that is connected to a common axle connecting two wheels via a drive belt. In an alternative preferred embodiment, the shuttle has two-wheel drive motors (7) connected directly to the wheels via a gearbox and the wheels move in synchrony with each other (shown in
The shuttle is equipped with two telescopic arms (4). These arms (4) are located on the platform (1) such that a loading area (1b) is in between the arms and the stationary side compartments (1a) are located on outer sides of the arms on the outer edges of the platform. The arms are configured to extend in the perpendicular direction to the moving direction of the shuttle. Telescopic arms (4) move in synchrony with each other, and they can extend to both directions perpendicularly against the moving direction of the shuttle. Both arms have their own arm drive motor (5). The arm drive motors are connected to the first parts of the arms and protrude the walls of the side compartments.
The telescopic arms of this disclosure are configured to extend in two directions such that the extension length of the arms in either direction is more than twice the depth of the platform. In retracted position the arms have a length equaling to the depth of the platform, but in fully extended position the length of the arm is more than the depth of the platform as shown in
The first part of the telescopic arm (13) does not move in relation to the platform, the second part (15) moves almost half of its length over the platform's edge and the third part (14) moves more than half of its length over the distal end of the second part so that the distal end of the third part is further away from the platform than the entire length of the third part. The length of each of the first, second and third part of the arm is preferably the same as the depth of the platform. In order to provide such telescopic arm capable of such overextension, the system requires specific features enabling the extension in a stable manner. The structure and function of the telescopic arms is described below in more detail.
In a preferred embodiment the second (15) and the third part (14) extend towards the shelves and crates that are located on the shelves. In the middle of the first part (13) there is an arm drive motor (5) driven pinion (25) in contact with a toothed rack (17) that is attached to the second part (15) (second part's toothed rack). The pinion's rotation causes the second part to extend almost as far as half the length of the second part (15) while still staying in contact with the rack (17). (See
Rollers (21) for the telescopic arm parts are located on the first (13) and the third part (14). (See
The telescopic arms (4) can also move in the direction of the moving direction of the shuttle. This movement changes the distance between the arms (4). To achieve this movement both arms (4) are connected with at least one ball screw or trapezoidal screw (9) mechanism (
Each arm has two linear bearings (10) that are mounted on shafts (8) connecting two halves of the platform i.e., the shafts extend between the two stationary side compartments and through a bottom portion of the first parts (13) of each arm. Each arm also has one screw nut that is mounted on a screw (9) that is supported on both ends of the platform. On one end of the screw there is a drive motor (6) that turns the screw (9). (See
At the distal ends of the third parts (15) of the arms there are rotating levers (11). (See
The levers (11) are in their vertical position while the telescopic arm is being extended to grab a crate. In one embodiment, while extending past the crate located on the shelf the optical sensor's line of vision is blocked by the crate. When the arms extend past the crate the optical sensors in each arm will see each other or in another embodiment the position of the arm part is confirmed by motor's encoder and the extending motion will stop, and the levers will rotate behind the crate. The arms (4) will move some distance closer to each other (via the turning of the screw (9) as described above) to minimize the crates movement from side to side during crate's moving and then the telescopic arms are retracted to pull the crate onto the platform.
To move the crate back to the shelf on the opposite side, the levers (11) are already at the back of the crate, or they are rotated to the back of the crate. The arms (4) are extended towards the shelves and the crate is pushed back with them. To move the crate/tote/parcel to the same side of the shelves the levers (11) on the other end of the arms are rotated behind the crate and the crate is pushed onto the shelf with them. The levers (11) are rotated to their vertical position and the arms are retracted back to the platform leaving the crate behind.
Power and signal cables are positioned on top of the telescopic arms first part (13) and underneath the third part's (14) upper section. One end of the energy chain (16) is mounted to one distal end of the first part (13) and the other end is mounted to the corresponding distal end of the third part (14) as is shown in
At one end of the platform there are supercapacitors.
This application claims priority to U.S. provisional application No. 63/358,971 filed on Jul. 7, 2022, and of U.S. provisional application No. 63/493,151 filed on Mar. 30, 2023.
Number | Date | Country | |
---|---|---|---|
63358971 | Jul 2022 | US | |
63493151 | Mar 2023 | US |