STORAGE SYSTEMS AND METHODS FOR RETRIEVING UNITS FROM A STORAGE SYSTEM

• US 20150127143A1
• Filed: 05/10/2013
• Published: 05/07/2015
• Est. Priority Date: 05/11/2012
• Status: Active Grant

• Current Assignee: Ocado Retail Limited (Ocado Group PLC)
• Original Assignee: Ocado Ltd (Ocado Group PLC)
• Inventors: Lindbo, Lars Sverker Ture, Stadie, Robert Rolf, Brett, Christopher Richard James, Whelan, Matthew Robert
• Granted Patent: US 9,682,822 B2
• Time in Patent Office: Days
• US Class Current: 700/218
• CPC Class Codes: B65G 1/0464 with access from above
• CPC Class Codes: B65G 1/137 with arrangements or automatic control means for selecting which articles are to be removed
• CPC Class Codes: G05B 15/02 electric

Abstract

A system and method suitable for storing multiple product lines in an automated warehouse environment are disclosed. The storage system includes a frame containing a plurality of stacks of containers, a first handling device capable of lifting a plurality of containers from a stack in a single operation, and a second independently moveable handling device capable of lifting a single container and moving the container laterally. The first and second handling devices can work together to remove a target container quickly and with minimum use of resources.

Claims

1. A storage system comprising:

a frame containing a plurality of stacks of containers;

a first handling device configured for lifting a plurality of containers from a stack in a single operation; and

a second handling device configured for lifting a single container and moving the container laterally;

wherein the first and second handling devices are disposed above the frame and are independently moveable to access different stacks.

2. A storage system according to claim 1, wherein the first handling device is configured for moving the plurality of containers laterally relative to a vertical orientation of the stack.

3. A storage system according to claim 1, wherein the first handling device is configured to lift a plurality of non-target containers from a stack containing a target container.

4. A storage system according to claim 3, wherein the second handling device is configured to lift the target container from the stack and to move the target container to a destination.

5. A storage system according to claim 1, wherein the first and second handling devices are configured differently from each other to perform different, dedicated functions.

6. A storage system according to claim 1, wherein the first handling device is configured to move the plurality of containers laterally to a temporary location at a top vertical position of a stack.

9. A storage system according to claim 1, comprising:

rails, wherein movement of each of the first and the second handling devices is guided in a horizontal plane by the rails, which are disposed above the frame; and

wherein each of the first and the second handling device comprises;

powered wheels arranged to engage with the rails.

15. A storage system according to claim 9, wherein the first handling device is moveable in a first horizontal plane above the frame, and wherein the second handling device is movable in a second horizontal plane that lies between the first horizontal plane and the frame.

16. A storage system according to claim 15, comprising:

a lower set of rails arranged above the frame for guiding the second handling device, and an upper set of rails arranged above the lower set of rails for guiding the first handling device.

17. A storage system according to claim 1, comprising:

a gantry to guide lateral movement of the first handling device above the frame, the second handling device being arranged to move beneath the gantry.

19. A storage system according to claim 1, wherein the first handling device comprises:

a robot vehicle equipped with a lifting device arranged to lift the plurality of containers from the stack in a single operation, the robot vehicle containing an aperture through which the plurality of containers can be lifted, the aperture being open to a side of the robot vehicle to allow the first load handling device to move laterally away from the plurality of containers once the plurality of containers has been placed in a temporary location.

22. A storage system according to claim 19, wherein the lifting device comprises:

a pair of telescopic lifting arms arranged on either side of the aperture, the storage system including vertically-extending spaces between the stacks of containers and the frame to allow the lifting arms to embrace the plurality of containers therebetween.

25. A storage system according to claim 19, wherein the lifting device comprises:

rods or cables arranged to engage with vertical channels formed in the side walls of the containers, wherein the rods or cables carry an anchor mechanism arranged to engage releasably with a container, the channels being open to sides of the containers to allow the rods or cables to be drawn outwards from the channels when the plurality of containers is lifted.

28. A storage system according to claim 25, wherein the lifting device comprises:

one or more spool devices configured to extend and retract the rods or cables.

30. A storage system according to claim 1, wherein the first handling device comprises:

a support frame for supporting a plurality of lifted containers.

31. A storage system according to claim 1, wherein the second handling device comprises:

a robot vehicle equipped with a crane device, the crane device being supported by a cantilever arm extending from the vehicle, wherein the vehicle includes first and second vehicle modules that support the crane device therebetween, the crane device including a gripper device configured to grip a container from above, the gripper device being suspended from cables that can be extended and retracted from the vehicle to move the gripper device vertically.

38. A storage system according to claim 1, wherein the second handling device comprises:

a robot vehicle equipped with a lifting device arranged to lift a single container from the stack.

39. A storage system according to claim 38, wherein the vehicle of the second handling device includes an aperture through or into which the container can be lifted, the lifting device including a pair of lifting arms arranged on either side of the aperture, and including a gripper device mounted between the ends of the arms and arranged to grip a container from above.

42. A storage system according to claim 1, wherein the frame comprises:

upright members and horizontal members arranged to guard against lateral movement of the stacks and to guide vertical movement of the containers.

43. A storage system according to claim 1, comprising:

one or more port locations at which containers can be removed from and/or added to the storage system, wherein the second handling device is configured for transporting a target container from a stack to a port location.

45. A storage system according to claim 1, wherein the containers are arranged to interlock or engage with one another in the vertical direction when formed in a stack, the storage system comprising:

a plurality of first handling devices, each being capable of lifting a plurality of containers from a stack in a single operation.

7-8. -8. (canceled)

10-14. -14. (canceled)

18. (canceled)

20-21. -21. (canceled)

23-24. -24. (canceled)

26-27. -27. (canceled)

29. (canceled)

32-37. -37. (canceled)

40-41. -41. (canceled)

44. (canceled)

46-53. -53. (canceled)

54. A method of retrieving a target container from a storage system, the storage system having a plurality of stacks of containers arranged in a frame, wherein the target container is located in a target stack beneath at least two non-target containers, the method comprising:

moving a first handling device to the target stack;

lifting a plurality of non-target containers from the target stack in a single lifting operation using the first handling device to allow access to the target container;

moving a second handling device to the target stack; and

lifting the target container from the target stack using the second handling device.

55. A method according to claim 54, comprising:

moving the second handling device underneath the first handling device to access the target stack; and

transporting laterally the plurality of non-target containers to a temporary location using the first handling device, before moving the second handling device to the target stack.

56-58. -58. (canceled)

59. A method of retrieving a target container from a storage system, the storage system having a plurality of stacks of containers arranged in a frame, wherein the target container is located in a target stack beneath at least two non-target containers, the method comprising:

moving a first handling device to the target stack;

lifting a plurality of non-target containers and the target container from the target stack in a single lifting operation using the first handling device;

transporting laterally the plurality of non-target containers and the target container to a temporary location using the first handling device;

depositing the target container in the temporary location;

removing the plurality of non-target containers from the temporary location;

moving a second handling device to the temporary location; and

lifting the target container from the temporary location using the second handling device.

60. The method of claim 59, comprising:

returning the plurality of non-target containers to the stack in a single operation using the first handling device.