HK40055789B - Storage system - Google Patents

Description

Storage system

This application is a divisional application of Chinese patent application No. 201680033686.1 entitled “Storage System” (based on international patent application No. PCT/EP2016/063244 filed on June 10, 2016, which entered the Chinese national phase on December 8, 2017).

Technical Field

This invention relates to a storage system.

Background Technology

The applicant’s known AutoStore system is a storage system comprising a three-dimensional storage grid in which storage boxes are stacked on top of each other to a certain height.

The storage grid is constructed as aluminum pillars interconnected by top rails. Multiple vehicles, or robotic vehicles, are configured on the top rails and can move horizontally on top of the storage grid.

Each vehicle is equipped with a lift for picking up, transporting, and placing the boxes stored in the storage grid.

The system also includes delivery and/or supply stations, where one or more items are picked up from storage bins, or where one or more items are filled into storage bins.

When items of a certain product type are stored in a storage bin and await retrieval from the storage grid, a robotic vehicle is configured to pick up the storage bin containing that product type and then transport it to a bin lifting device. The bin lifting device then transports the storage bin to a transport and/or supply station, where items of that product type are retrieved from the storage bin. Storage bins containing any remaining items of that product type are then returned to the storage grid via the bin lifting device and the robotic vehicle.

The same procedure is used to refill items into the storage grid. First, items are filled into storage bins at the delivery and/or supply station. Then, a bin lifting device lifts the storage bin to the upper level, where a robotic vehicle delivers the storage bin to its correct position within the storage grid.

Storage control and communication systems can be used to monitor inventory, the location of storage bins (within storage grids and/or during transport), fill levels, etc. The storage control and communication system may also include a control system (or be configured to communicate with a control system), which controls the robotic vehicle to avoid collisions.

It has been found that storage systems take a considerable amount of time to transport storage boxes from the top of the grid to the delivery and/or supply station. Therefore, the object of this invention is to provide a more time-efficient storage system.

Summary of the Invention

This invention relates to a storage system for storing product items, comprising a grid structure having a top layer. A plurality of first storage boxes are configured to be vertically stacked within the grid structure, wherein each first storage box is configured to contain at least one product item; a vehicle is configured to move horizontally at the top layer of the grid structure and is further configured to pick up, transport, and place the first storage boxes at desired locations within the grid structure. The invention is characterized by…

The storage system further includes a robotic device comprising a movable arm having a picking mechanism at one end.

-The robotic device is configured to move stored items between a first position and a second position via its picking mechanism;

- The first position is the location of the first storage box stored in the storage grid.

It should be noted that even if each first storage box is configured to hold at least one product item, it is entirely possible for an empty first storage box to be stored in the storage grid.

Various aspects of the invention are apparent from the appended claims.

Attached Figure Description

Embodiments of the present invention will be described below with reference to the accompanying drawings, wherein:

Figure 1 discloses a prior art storage system;

Figure 2 schematically shows a side view of an embodiment of the storage system according to the present invention;

Figure 3 shows the embodiment of Figure 2 from above;

Figure 4 shows an alternative embodiment from above;

Figure 5 shows yet another embodiment from above;

Figure 6 shows a side view of the embodiment of Figure 5;

Figure 7 shows another embodiment from the side.

Detailed Implementation

Referring now to Figure 1, a storage system 10 is shown, which includes a grid structure 20 for storing products in storage boxes 30. Each storage box 30 is configured to hold one or more product items.

As shown in Figure 1, a certain number of storage boxes 30 are configured to be stored vertically stacked within a grid structure 20.

The vehicle 40 is configured to move horizontally at the top layer L0 of the grid structure 20, and is further configured to pick up, transport, and place the first storage box 30 at a desired location.

The storage system 10 further includes a delivery and/or supply station 60. The delivery and/or supply station 60 is located on the floor of the building, on which storage grids 20 are configured. The number of floor layers is denoted as Ln, where n is the number of stackable storage boxes 30 in the storage grids 20. The delivery and/or supply station 60 is used to prepare product items picked up from the grid structure 20 for delivery to a recipient (e.g., the buyer of the product items). The delivery and/or supply station 60 is also used to register product items from suppliers (e.g., the manufacturer of the product items) before placing them within the grid structure 20.

It should be noted that there may be several transport and/or supply stations 60, and at least one of these transport and/or supply stations 60 may be divided into a transport station and a supply station, wherein the transport station handles product items picked up from the grid structure, and wherein the supply station handles product items to be placed in the grid structure.

The system in Figure 1 also includes a container lifting device 50, which is configured to transport storage containers 30 between the top layer L0 of the grid structure 20 and the transport and/or supply station 60. In Figure 1, this transport is shown in the vertical direction.

The storage system 10 shown in Figure 1 is considered to be prior art.

In the following text, the term "first storage box" is used for the storage box 30 stored in the grid structure 20, and the storage box will be transported to the delivery and/or supply station 60 via the box lifting device 50.

First Embodiment - Figures 2 and 3

Now refer to Figures 2 and 3. As in Figure 1, the storage system 10 includes a storage grid 20, which has stacked storage bins 30. Layers L0, L1, L2-Ln are shown.

Vehicle 40 is also shown. The specific vehicle 40 shown in Figure 2 is considered well-known. Prior art vehicles 40 can travel horizontally (along the horizontal x-axis and horizontal y-axis, as shown in Figure 1) on layer L0 of the grid structure 20. Vehicle 40 includes a lifter (not shown) for picking up storage bins 30 and transporting them to a desired location within the grid structure 20, for example...

- Via container lifting device 50 from grid structure 20 to transport and/or supply station 60

-From the transport and/or supply station 60 to the storage grid 20 via the container lifting device 50

- Inside the grid structure 20.

For example, if the desired product item is located in storage box 30 at layer L3 and below other storage boxes 30, vehicle 40 can first move the upper storage box 30 (at layers L2 and L1) that is located above the storage box 30 to be picked up to another available location on the top of the grid structure to reach the desired storage box 30 at layer L3.

It should be noted that the specific design of the prior art vehicle 40 shown in Figure 2 presents a possible temporary storage of the storage box 30 on layer L0. In Figure 2, the storage box 30 is shown located at position A on layer L0. Of course, this storage box 30 at position A will prevent access to the storage box located directly below it. Furthermore, the storage box 30 at position A will also represent an obstacle to the movement of the vehicle 40.

Figure 2 shows that the storage system 10 also includes a robotic device 70.

The robot device 70 includes a base 71 connected to a movable arm 72. As shown in Figure 2, the movable arm 72 includes a first arm portion 72a and a second arm portion 72b. The first arm portion 72a is connected to the base 71, and the second arm portion 72b is connected to the first arm portion 72a via a pivot joint 72c. The robot device 70 further includes a picking mechanism 74 at the outer end of the second arm portion 72b.

It should be noted that the robotic device 70 itself is considered well-known, as several robots of this type are available for purchase.

Figure 2 shows that the base 71 of the robot device 70 is located at a distance above layer L0.

The robot device 70 is configured to move the stored item 80 between a first position A and a second position B (FIG. 3) via its picking mechanism 74. Furthermore, the robot device 70 may be configured to move all of the first and/or second storage boxes 30, 38 via its picking mechanism 74.

The robotic device 70 can be positioned during use so that its movable arm 72 is above or below the top layer L0 of the storage grid 20 (e.g., layer L1). Therefore, the first position A can be the location of a first storage box 30 stored at the top layer L0 or stored at the layer L1 directly below the top layer L0 of the storage grid 20. Furthermore, the storage box 30 at layer L1 can only be retrieved if there is no storage box 30 at the same x and y positions on layer L0 above the storage box 30 at layer L1.

The robotic device 70 is configured to communicate with the vehicle control system of the vehicle 40 to, for example, avoid collisions between the vehicle 40 and the robotic device 70. It should be noted that several methods can achieve this – there could be a main control system to control the robotic device 70 and each vehicle 40 in detail. For example, the main control system could define time slots (or time intervals) for vehicle movement in an area near the robotic device 70, during which the robotic device 70 is commanded to move its arm to a position where a collision will not occur. Then, another time slot could be defined, in which the vehicle 40 is commanded to move away from the area near the robotic device 70. Alternatively, the control system could be of a type where the robotic device 70 and the vehicle 40 have more or less autonomy. For example, the robotic device 70 and the vehicle 40 could be equipped with sensors connected to an internal control system located on each vehicle/robot 40.

The aforementioned vehicle control system may be part of the aforementioned storage control and communication system, or may be configured to communicate with the aforementioned storage control and communication system.

In Figures 2 and 3, the first location A is the position of the first storage bin 30 stored in or on the storage grid 20, while the second location B is the position of the conveyor system (generally indicated by reference numeral 90). The conveyor system 90 is configured adjacent to the storage grid 20. The second location B may be the position of the second storage bin 38 configured on the conveyor system 90, as shown in Figures 2 and 3, or it may be shown as the position of the conveyor system 90 itself.

The conveyor system 90 may include a conveyor belt, conveyor chain, or any other type of conveyor suitable for conveying product items 80 or a second storage tank 38 that houses one or more storage items 80. The conveyor system 90 may also include several such conveyors.

The conveyor system 90 can be configured to convey product items 80 or a second storage box 38 containing product items 80 to the transport and/or supply station 60, thereby acting as the aforementioned robotic lifting device 50.

Figure 2 shows that the conveyor system 90, located near the robot device 70, is positioned at a height Hc equal to or higher than the height HL1 of the layer L1 directly below the top layer L0. Of course, other parts of the conveyor system 90 may be located at lower heights.

The present invention enables an increase in the efficiency of the storage system 10 by avoiding (completely or partially) transporting the first storage box 30 to the transport and/or supply station 60 via the box lifting device 50.

Alternatively, the present invention enables the delivery and/or supply station 60 to be located on other floors (e.g., at a height corresponding to the height shown in FIG2), and in a location adjacent to a room where the storage grid 20 is configured.

As described above, the first storage box 30 is designed to be stacked on top of each other in the grid structure 20 and to be transported by the vehicle 40 and the box lifting device 50.

However, the second storage box 38 can also be of a different type. The second storage box 38 can be a cardboard box used to distribute product items 80 to recipients, such as the buyer of product items 80 described above. Therefore, the robotic device 70 can perform some or all of the work operations currently performed more or less manually at the delivery and/or supply station 60. For certain types of products, only the closing operation of the cardboard box and/or the operation of affixing address labels to the cardboard box remain.

Alternatively, the second storage container 38 may be substantially the same type as the first storage container 30, wherein the robotic device 70 picks up several or all of the ordered product items and delivers them to a receiver. The second storage container 38 is then transported via a conveyor system 90 to a delivery and/or supply station 60, where the order is completed by repackaging the product items 80 from the second storage container 38 into cardboard boxes. This would be necessary for product items 80 that require special care, such as fragile product items 80. This operation remains more efficient because all product items of an order arrive at the delivery and/or supply station 60 simultaneously.

Referring again to Figures 2 and 3, the conveyor system 90 is shown to include a first conveyor 90a and three conveyors 90b, 90c, and 90d. The first conveyor 90a conveys the second storage box 38 in a first direction (indicated by arrow x in Figure 3), and the three conveyors 90b, 90c, and 90d then convey the storage box 38 in parallel in a second direction (indicated by arrow y in Figure 3).

Referring now to Figure 3. Here, the dashed box A1 in the grid structure 20 represents the area accessible to the first robotic arm, and the dashed box B1 outside the grid structure 20 represents the area accessible to the second robotic arm. The product item 80 at position A is shown in the first storage box 30 within area A1, and the position B for the product item 80 is shown in the second storage box 38 within area B1. As shown, the second area B1 is located on three parallel conveyors 90b, 90c, and 90d, close to the robotic device 70.

In Figure 3, the dashed circle C represents the maximum reach of the picking mechanism 74 of the robot device 70. Of course, the number of first storage boxes 30 in the first area A1 and the number of second storage boxes 38 in the second area B1 can be changed according to the size of the robot device 70 and the size of the storage boxes 30 and 38.

Therefore, the storage control and communication system is configured to control vehicle 40 to place multiple first storage boxes 30 within the first robotic arm 72 reachable area A1 of storage grid 20, and then control robot device 70 to move product items 80 from the first storage boxes 30 in the first robotic arm 72 reachable area A1 of storage grid 20 to the second storage boxes 38 placed outside storage grid 20 in the second robotic arm 72 reachable area B1.

Once all product items 80 have been placed into the second storage box 38, the box 38 is transported to the next station via conveyor 90b for further processing (dispatch, repackaging, or other operations at transport and/or supply station 60, etc.). Empty second storage boxes 38 are supplied via conveyor 90a, and robotic device 70 can move the second storage boxes 38 from the first conveyor 90a to free space within the second area B1.

Alternatively, conveyors 90b, 90c, and 90d may transport an empty second storage box 38 toward the robot device 70 (opposite to the direction of arrow y), and the second storage box 38 containing product items 80 may be moved onto the first conveyor 90a for further processing.

Alternatively, the robot device 70 is used to supply product items 80 to the storage grid 20. Here, storage boxes 38 can be delivered to the robot device 70, and the robot device 70 is used to fill the first storage box 30, which is then moved by the vehicle 40 to the desired location within the storage grid 20.

According to the first embodiment, the prior art box lifting device 50 can be partially or completely omitted in the storage system. This is highly advantageous because in some prior art storage systems, the box lifting device 50 can have a height of 5 meters or more, which consumes a significant amount of total transport time. Omitting the prior art box lifting device 50 may also alleviate logical problems related to the efficient sorting of, for example, product items 80.

Second embodiment - Figure 4

Referring now to Figure 4. The second embodiment has many features common to the first embodiment described above, and the same reference numerals are used for those common features. For efficiency, only the differences between the second and first embodiments will be described here.

In a second embodiment, the conveyor system 90 includes a first conveyor 90a and a second conveyor 90b arranged in parallel. The first conveyor 90a and the second conveyor 90b can move in the same direction or in opposite directions. As shown in FIG3, a first robotic arm-accessible area A1 is shown in the storage grid 20, and a second robotic arm-accessible area B1 is shown on the first and second conveyors 90a.

Third embodiment - Figures 5 and 6

Referring now to Figures 5 and 6. The third embodiment has many features common to the first embodiment described above, and the same reference numerals are used for those common features. For efficiency, only the differences between the third and first embodiments will be described here.

In the third embodiment, the robotic device 70 is fixed to the grid structure 20 and may be surrounded by vertically stacked storage bins 30. Here, the conveyor system 90 is disposed on top of the storage grid 20, rather than on its sides. Furthermore, the conveyor system 90 includes only one conveyor 90a. In this way, the central portion of the storage grid 20 is also within the reachable area of the robotic arm. In Figure 5, a first robotic arm reachable area A1 is shown in the storage grid 20, and a second robotic arm reachable area B1 is shown on the conveyor 90a.

Preferably, the conveyor system 90 is positioned at height HV, corresponding to the height of the vehicle 40 above the top layer L0 (see the dashed line in Figure 6). Therefore, the vehicle 40 can pass beneath the conveyor system 90.

Fourth embodiment - Figure 7

The base 71 of the robot device 79 is supported by a support beam above the iron bracket or grid structure 20, such as a bracket/beam supporting the roof of a building, with the storage grid 20 disposed below the bracket/beam. This robot device 79 can be fixed at a specific location above the grid structure 20, or it can be moved, for example, by sliding on the bracket/beam.

In this embodiment, a conveyor system 90 may also be provided with a conveyor 90a at a height HV corresponding to or above the height of the vehicle 40, allowing the vehicle 40 to pass under the conveyor belt. A conveyor system 90 may also be provided with a conveyor 90b within the grid 20 (e.g., at approximately layer L1 or L2).

It should be noted that in all the above embodiments, the storage system 10 will be suited to its intended use. The storage system 10 may include one or more such robotic devices 70. The robotic devices 70 may be disposed on the side of the storage grid (as in the first and second embodiments described above), and/or integrated into the storage grid (as in FIG. 5), or on top of the storage grid (as in FIG. 6).

The storage control and communication system can also be configured according to its intended use. For example, the storage control and communication system can be configured to analyze multiple pick commands and then determine the most frequently needed product item 80 from the pick commands. Based on this, the vehicle 40 can be configured or controlled to place the first storage box 30, which contains the most frequently needed product item 80, in the first area A1.

Furthermore, the storage control and communication system can be additionally configured to control the robotic device 70 to move product items 80 from more than one first storage bin 30 in an area A1 accessible by a first robotic arm 72 of the storage grid 20 to at least one second storage bin 38 in an area B1 accessible by a second robotic arm 72 located outside the storage grid 20. As described above, the robotic device 70 will then be able to execute pick-up commands (fully or partially), thus making the pick-up operation more efficient.

In the foregoing description, various forms of components according to the invention have been described with reference to illustrative embodiments. Specific numbers, systems, and configurations are presented for illustrative purposes to provide a thorough understanding of the systems and their operation. However, this description is not to be construed as limiting. Various modifications and variations to the illustrative embodiments of the disclosed technical features, as well as other embodiments of the system, which will be apparent to those skilled in the art, are considered to be within the scope of the invention.

Claims (12)

1. A storage system (10) for storing product articles (80), comprising: A mesh structure (20), wherein the mesh structure has a top layer (L0); A plurality of first storage boxes (30) are configured to be stored vertically stacked in the grid structure (20), wherein each first storage box (30) is configured to contain at least one product item (80); The vehicle (40) is configured to move horizontally at the top layer (L0) of the grid structure and is further configured to pick up, transport, and place the first storage box (30) at a desired location within the grid structure (20); A robotic device (70) includes a movable arm (72) having a picking mechanism (74) at one end. The robot device (70) is configured to move product items (80) between a first position (A) and a second position (B) via its picking mechanism (74), wherein the first position (A) is the position of a first storage box (30) stored in the grid structure (20); The storage system (10) further includes a storage control and communication system, which is configured to: Control the vehicle (40) to place a plurality of first storage boxes (30) in a first area (A1) accessible by the movable arm (72) of the grid structure (20); and The robot device (70) is controlled to move the product item (80) from at least one first storage box (30) in a first area (A1) accessible by the movable arm (72) of the grid structure (20) to at least one second storage box (38) in a second area (B1) accessible by the movable arm (72) outside the grid structure (20). The first location (A) is the location of the first storage box (30) stored at the top layer (L0) or at the layer (L1) directly below the top layer (L0) in the grid structure (20). The second position (B) is the position of the conveyor system (90) located adjacent to the grid structure (20). 2. The storage system (10) according to claim 1, wherein the robotic device (70) is positioned during use such that its movable arm (72) is above the top layer (L0) of the mesh structure (20) or in a layer (L1) directly below the top layer (L0). 3. The storage system (10) according to claim 1, wherein the second position (B) is the position of the second storage box (38) disposed on the conveyor system (90). 4. The storage system (10) according to claim 1, wherein the conveyor system (90) is positioned at a height (Hc) equal to or higher than the height (HL1) of the layer (L1) located directly below the top layer (L0). 5. The storage system (10) according to claim 1, wherein the robotic device (70) is configured to move the first storage box (30) and/or the second storage box (38) by means of its picking mechanism (74). 6. The storage system (10) according to claim 1, wherein the robotic device (70) is configured to communicate with a vehicle control system that controls the vehicle (40) to avoid collisions between the vehicle (40) and the robotic device (70). 7. The storage system (10) according to claim 1, wherein the conveyor system (90) is configured to convey the product article (80) or the second storage box (38) containing the product article (80) to the delivery and/or supply station (60). 8. The storage system (10) according to claim 7, wherein the system includes a box lifting device (50) configured to transport the first storage box (30) between the top layer (L0) of the grid structure (20) and the transport and/or supply station (60) in a vertical direction. 9. The storage system (10) according to claim 1, wherein the storage control and communication system is further configured to: -Analyze multiple pick commands; - Identify the most frequently needed product items from the pick command (80); - Place the first storage box (30) containing the most frequently needed product items (80) in the first area (A1). 10. The storage system (10) according to claim 9, wherein the storage control and communication system is further configured to: - Control the robot device (70) to move product items (80) from more than one first storage box (30) in the first area (A1) of the grid structure (20) to at least one second storage box (38) placed in the second area (B1) outside the grid structure (20). 11. The storage system (10) according to any one of claims 1 to 10, wherein the robotic device (70) further includes a base (71) supported by a support beam above the mesh structure (20), and wherein the movable arm (72) is operatively coupled to the base (71). 12. The storage system (10) according to claim 11, wherein the grid structure (20) has an outer boundary that surrounds the base (71) of the robot device (70) when projected onto a floor on which the grid structure (20) is arranged.