Patent Application
20250206527
The present invention relates to a storage system for making product items stored in storage containers accessible to a person. The present invention also relates to a method for making product items stored in storage containers accessible to a person.
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-supporting.
Each prior art container handling vehicle 201,301,401 comprises a vehicle body 201a,301a,401a and first and second sets of wheels 201b, 201c, 301b, 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 below the rails 110,111, 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,401a as shown in
The cavity container handling vehicle 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 110,111 may comprise two parallel tracks. In other rail systems 108, each rail in one direction (e.g. an X direction) may comprise one track and each rail in the other, perpendicular direction (e.g. a Y direction) may comprise two tracks. Each rail 110,111 may also comprise two track members that are fastened together, each track member providing one of a pair of tracks provided by each rail.
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 (e.g. 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.
NO344898 describes a storage system comprises a picking and/or supply station with a drawer device, where the drawer device comprises a storage container with a compartment for temporarily storing a product item to be picked from or supplied to the storage system. The drawer device is configured to be in a closed state or in an open state; where an person is prevented from accessing the compartment in the closed state and where the person is allowed to access to the compartment in the open state. Identification of the person may be required to open the drawer.
One object of the present invention is to allow a person to access the content of one or a plurality of storage containers.
More specifically, the object of the present invention is to allow the person to access the content directly from the one or plurality of storage containers.
The present invention relates to a storage system comprising:
Hence, the person may put his/her hand through the side opening, the bottom opening and the top opening and pick the product item directly from the storage container.
In one aspect, the storage system comprises a container handling vehicle operating on the rail system, wherein the container handling vehicle comprises a lifting device which is configured for vertical transportation of one of the storage containers or the access frames within the storage columns and for horizontal transportation of one of the storage containers or the access frames above the rail system.
Hence, the storage containers to which access should be granted may be arranged and rearranged automatically by means of the container handling vehicle.
In one aspect, the storage containers and the frames each comprise a connection interface on an upper surface and wherein the lifting device of the container handling vehicle comprises a gripper that is configured to engage the connection interface such that the container handling vehicle is able to lift any of the storage containers or frames using the lifting device.
In one aspect, the access frame comprises a rectangular top portion and legs protruding downwardly from the rectangular top portion, wherein the top portion defines an upper stacking interface allowing a storage container to be stacked above the access frame.
In one aspect, the frame comprises four legs, each leg protruding downwardly from corners of the rectangular top portion.
In one aspect, the side opening is defined by an area between one side of the rectangular top portion and two of the downwardly protruding legs.
In one aspect, the bottom opening is defined by an area between the lower end of the downwardly protruding legs.
In one aspect, the access frame comprises cross members connected between lower ends of at least some of the downwardly protruding legs, wherein the bottom opening is defined by the lower ends of the downwardly protruding legs together with the cross members.
In one aspect, the access frame comprises three cross members arranged in a U-shaped configuration with its open end facing towards the side opening.
Hence, as there is no cross member at the side opening, the upper edge of the storage container is forming the lower part of the side opening. This will increase the area of the side opening without increasing the height of the access frame.
In one aspect, the lower end of the downwardly protruding legs together with the cross members are forming a rectangular bottom portion.
In one aspect, lower ends of the downwardly protruding legs defines a lower stacking interface allowing the access frame to be stacked above storage containers or other access frames.
In one aspect, access frames are stacked alternately with storage containers in one or more of the stacks, optionally all of the stacks, along one side of a volume defined by the structure.
In one aspect, side openings of access frames in a first row of stacks are aligned with each other in a horizontal direction.
In one aspect, as the access frames and the containers are stacked above each other, the side openings of access frames in a first row of stacks are also aligned with each other in a vertical direction.
In one aspect, the side openings of access frames in the first row of stacks are facing a access area which is accessible for a person.
In one aspect, each storage container comprises a base with four sides protruding upwardly from the base, wherein the top opening is defined by an upper edge of the four sides.
In one aspect, one side of the storage container has a height which is lower than a height of other sides, and wherein the one side of the storage container is aligned with the side opening when an access frame is stacked above the storage container.
Hence, the side opening may be further increased without increasing the height of the access frame.
In one aspect, the one side of the storage container is facing the access area.
In one aspect, the one side may be referred to as a front side, a person-facing side or a public-area facing side.
In one aspect, side openings of access frames in a second row of stacks are parallel with the first row of stacks, wherein the first row is adjacent to the second row and wherein the side openings of the access frames in the first row are facing away from the side openings of the access frames in the second row.
In one aspect, the side openings of the access frames in the second row of stacks are facing the access area to provide access for a person.
Hence, the storage containers and access frames in the first and second rows form a shelf from which product items can be picked directly from the respective storage containers via the access frames.
In one aspect, the access frame comprises at least one light to illuminate an interior of a storage container.
In one aspect, the storage system comprises a barrier for covering at least one of the stacks of storage containers and access frames during elevation of a storage container or access frame from the one stack and/or during lowering of a storage container or access frame into the one stack.
Hence, the barrier is protecting the person from accessing the storage containers and access frames during vertical movement of the storage containers and access frames. Preferably, the barrier is extending over a larger area than just the one stack.
In one aspect, the storage system comprises a control system for controlling the container handling vehicles.
In one aspect, the storage system comprises:
The second structure may be the framework structure of a prior art storage system. Here, the storage containers are stacked directly above each other in the stacks, and hence, the content of the storage containers stacked in the stacks are not accessible for a person.
In one aspect, the control system of the storage system is integrated with, or is a part of, the control system of the automated storage and retrieval system.
The present invention also relates to a method for making product items stored in storage containers accessible to a person, wherein the method comprises the steps of:
In one aspect, the steps of stacking comprises the step of:
In one aspect, the method further comprises the step of:
In one aspect, the set of storage containers in one stack may comprise 2-12 storage containers, preferably 3-8 storage containers, even more preferred 3-6 storage containers.
According to the above, it is achieved a storage system in which access to the content of storage containers is achieved by a person moving along the stacks of storage containers and accessing frames. The stacks and accessing frames may be arranged and rearranged automatically by means of the container handling vehicles. The first structure of the storage system may be a part of a microfulfilment centre or warehouse. The second structure of the storage system may be a storage from which containers containing product items are moved to the first structure. When storage containers in the first structure are empty or near empty, they are returned either to the second structure or to a replenishment station. The person will typically not be able to access containers stacked in the second structure.
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.
It is now referred to
The framework structure 100 can be of any size. In particular it is understood that the framework structure can be considerably wider and/or longer and/or deeper than disclosed in
On the right side of
The storage system 2 further comprises a rail system 18 provided on top of the upright members 12. As shown in
The first structure 10 is in many ways identical to the prior art framework structure 100, in that the upright members 12 may be of the same type as the upright members 102, and further in that the columns 15 are of the same dimension as the storage columns 105. However, there are some differences, which will be described further in detail below.
It is now referred to
The main difference between the storage container 106 in
In
The access frame 20 comprises a side opening 20a indicated by a dashed rectangle in
The storage container 6, the storage container 106 and the access frame 20 comprise a connection interface CI provided on their respective upper surfaces, wherein a lifting device 403 of the container handling vehicle 201, 301, 401 comprises a gripper 304, 404 that is configured to engage the connection interface CI such that the container handling vehicle 201; 301; 401 is able to lift the storage container 6, storage container 106 or the access frame 20 using the lifting device 403.
The top portion 21 of the access frame 20 defines an upper stacking interface USI allowing a storage container 6, 106 or other access frames 20 to be stacked above the access frame 20. The lower ends of the downwardly protruding legs 22 together with the cross members 23 define a lower stacking interface LSI allowing the access frame 20 to be stacked above storage containers 6, 106 or other access frames 20.
It should be noted that also the storage containers 6, 106 comprises such upper stacking interfaces USI and lower stacking interfaces LSI. Consequently, the containers 6, 106 and access frame 20 can be stacked above each other in any desired sequence.
It is now referred to
The plurality of access frames 20 are arranged in an alternating manner with consecutive storage containers 106, each storage container 106 being spaced from one above by an access frame 20. Hence, a set S, indicated in
In
In the embodiment shown in
Hence, the person P may put his/her hand through the side opening 20a, the bottom opening 20b and the top opening 106a and pick the product item 80 directly from the storage container 106.
It should further be noted that in
It is now referred to
The first row R1 of stacks 17 and the second row R2 of stacks 17 form a shelf-like structure from which the person P may retrieve desired product items 80.
Consequently, the person P may access storage containers 106 in the first row R1 of stacks 17 from one side of the shelf-like structure, while the person P may access storage containers in the second row R2 of stacks 17 from the opposite side of the shelf-like structure. As indicated in
It is also shown in
It is now referred to
It is now referred to
The operation of the storage system 2 will now be described. In
In the present example, storage containers 106 of the prior art type are used. However, also storage containers 6 shown in
In the present embodiment, the access area AA is a warehouse where customers have access. The customers may then walk between the rows R1, R2 and retrieve products 80 from the storage containers via the access frames 20. However, the access area AA may also be a restricted area only accessible for persons employed to perform picking operations.
Initially, it is assumed that the first structure 10 is empty, i.e. that no storage containers or access frames are stored within the columns 15 of the first structure 10. This may be necessary for cleaning purposes etc, preferably in the evening after closing of the access area AA.
The control system 50 is then configured to control the container handling vehicle to move a first storage container 106 from the second structure 100 and stack it, i.e. insert it, into one of the storage columns 15 of the first structure 10. Then the container handling vehicle or another container handling vehicle is controlled to stack a first access frame 20 directly above the first storage container 106. In a next step, the container handling vehicle or another container handling vehicle is controlled to stack a second storage container 106 directly above the first access frame 20. In a next step again, the container handling vehicle or another container handling vehicle is controlled to stack a second access frame 20 directly above the second storage container 106.
The above actions are repeated for that stack until a desired height of storage containers and access frames are achieved, and the above actions are repeated for the other stacks in the first structure 10.
As the control system 500 and/or the control system 50 know the content of each storage container, containers containing products of the same category may be stacked above each other or in stacks adjacent to each other in the same row of stacks.
As shown schematically in
By monitoring the number of product items retrieved from the respective storage containers, it is possible to determine if some storage containers are empty or near empty. In such a case, it can be determined that the empty or near empty storage containers are to be replaced by full or near full storage containers. If the storage container is empty, this is preferably done by removing the empty storage container and moving a full or near full storage container from the framework structure 100 to the first structure 10, either to the same location as the empty or near empty storage container or to another location within the first structure 10. If the storage container is near empty, it can be moved to a replenishment station for replenishing.
This can be done during the opening hours of the warehouse. In this case, the barrier B should be applied to the structure 10 to prevent injuries caused by moving containers and access frames within the storage columns 15. Alternatively, this can be done after the opening hours of the warehouse. As no persons are present in this case, no barrier B is required.
Some further alternative embodiments will now be described.
Initially, it should be noted that the access frame 20 can be regarded as having two or four side openings, depending on how the columns and stacks are arranged in the first structure 10. The access frame shown in
It is now referred to
It is now referred to
It is now referred to
It should be noted that in the embodiment of
Hence, the side opening 20a may be further increased without increasing the height H20 of the access frame 20.
It is now referred to
In the embodiment shown in
It is now referred to
In the preceding description, various aspects of storage system according to the invention 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 |
|---|---|---|---|
| 20220389 | Mar 2022 | NO | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2023/057588 | 3/24/2023 | WO |
