Automated storage and retrieval system

• US 6,325,586 B1
• Filed: 12/08/1999
• Issued: 12/04/2001
• Est. Priority Date: 12/08/1999
• Status: Expired due to Fees

• Current Assignee: Protosight Incorporated, Sierra Design Group (Scientific Games Corporation)
• Original Assignee: Protosight Incorporated
• Inventors: Loy, David H.
• Primary Examiner(s): Bratlie, Steven A.
• Application Number:
  US09/456,903
• Time in Patent Office: 727 Days
• Field of Search: 414/281, 414/282, 414/283, 414/331.07
• US Class Current: 414/281
• CPC Class Codes: B65G 1/02 Storage devices furniture A47B; shop fittings A47F
• CPC Class Codes: B65G 1/0414 provided with satellite cars adapted to travel in storage racks
• CPC Class Codes: B65G 1/1375 the orders being assembled on a commissioning stacker-crane or truck
• CPC Class Codes: B65G 2209/10 Partial order forming

Abstract

Case handling magazines and robot end effector for an automated storage and retrieval system in a warehouse include comb shelves for holding individual cases of goods. The case handling magazines are transported by conventional automated pallet handling stacker cranes and transfer cars. The magazine comb shelves and robot end effector have load carrying teeth spaced apart along the length of the shelves. The magazines include storage magazines for holding cases in conventional storage bays and transfer magazines for transferring cases to and from the storage magazines. The comb shelves of the storage magazines and transfer magazines are complementary with one another and enable the teeth of the comb shelves to intermesh with each other for transferring cases from a loaded comb shelf to an empty comb shelf. The robot end effector and some magazines include movable comb shelf segments that enable the selective transfer of all or less than all the cases on the loaded comb shelf to the unloaded comb shelf.

Claims

1. A case handling and storage apparatus for a warehouse comprising:

a storage rack defining a plurality of magazine storage bays;

a case storage magazine supported in a first magazine storage bay and a case transfer magazine movable into and out of the magazine storage bay between a first position outside of the first bay and a second position in the first bay adjacent to the case storage magazine for case transfer between the magazines;

each magazine comprising a frame and a pair of horizontal comb shelves on the frame, the frame of each magazine comprising a support surface, the support surface of the case storage magazine engaging the storage rack to support the case storage magazine in the first bay;

each comb shelf comprising a support member extending along the length of the shelf, a connection mounting the support member to a magazine frame, and a plurality of case-support teeth spaced along the support member and fixed to the support member, the teeth extending outwardly away from the support member to free ends;

the teeth of each comb shelf of the case transfer magazine located between and to one side of the teeth on an adjacent comb shelf of the case storage magazine when the case transfer magazine is in the second position such that the teeth of adjacent comb shelves are vertically movable past each other;

the case transfer magazine comprising a drive surface connected to the comb shelves for conjoint vertical movement with the comb shelves, the drive surface and the comb shelves movable between raised and lowered positions when the case transfer magazine is in the second position wherein the teeth of each comb shelf of the case transfer magazine move from the one side to the other side of the teeth of the adjacent comb shelf of the case storage magazine;

a first drive mechanism to move the case transfer magazine between the first and second positions, the support surface of the case transfer magazine engaging the first drive mechanism to support the case transfer magazine when moving between the first and second positions; and

a second drive mechanism to move the teeth of the comb shelves of the case transfer magazine vertically for case transfer, the second drive mechanism comprising a vertically movable drive member, the drive member engageable with the drive surface of the case transfer magazine when the case transfer magazine is in the second position to move the drive surface between raised and lowered positions, whereby the teeth of each comb shelf of the case transfer magazine pass through the teeth of an adjacent comb shelf of the case storage magazine to transfer a supported case between adjacent comb shelves.

2. The case handling and storage apparatus of claim 1 wherein:

the storage rack comprises a pair of first horizontal beams located on opposite sides of the first storage bay and a pair of second horizontal beams located on opposite sides of a second storage bay, each beam having an upwardly facing support surface adjacent the first or second storage bay;

the support surface of the case storage magazine comprises a pair of spaced apart downwardly facing surfaces, each surface abutting a support surface of a respective first beam whereby the case storage magazine is supported against gravity on the first beams; and

the support surface of the case transfer magazine comprises a pair of spaced apart downwardly facing surfaces, each surface abutting a support surface of a respective second beam when the case transfer magazine is in the first position whereby the case transfer magazine is supported against gravity in the second bay.

3. The case handling and storage apparatus of claim 1 comprising a transport vehicle for carrying the case transfer magazine between the first and second positions, the vehicle comprising a chassis;

the first drive mechanism being attached to the chassis and comprising a drive train for moving the transport vehicle; and

the support surface of the case transfer magazine engaging the chassis when the case transfer magazine is carried by the transport vehicle.

4. The case handling and storage apparatus of claim 3 wherein the storage rack comprises a plurality of horizontal rails extending between the first and second positions, and the drive train engages the rails and drives the transport vehicle along the rails.

5. The case handling and storage apparatus of claim 1 wherein the frame of one of the case storage and case transfer magazines comprises a pair of spaced apart outer support members, one comb shelf of the one magazine mounted on one outer support member and the other comb shelf of the one magazine mounted on the other outer support member;

the frame of the other of the case storage and case transfer magazines comprises a central support member having opposite sides, one comb shelf of the other magazine mounted on one side of the central support member and the other comb shelf of the other magazine mounted on the other side of the central support member; and

the central support member is located between the comb shelves of the one magazine when the case storage and case transfer magazines are in the second position.

6. The case handling and storage apparatus of claim 5 wherein the one magazine is the case storage magazine, the comb shelves of the case storage magazine fixedly attached to the outer frame members;

the other magazine is the case transfer magazine, the comb shelf attachments of the case transfer magazine movably mounted to the central support member for vertical movement of the comb shelves along the central support member;

the drive surface of the case transfer magazine comprises a plurality of drive surfaces, each drive surface connected to a respective comb shelf attachment for conjoint movement with the comb shelf attachment, the comb shelf segment movable between raised and lowered positions; and

the second drive mechanism comprises a plurality of drive members, each drive member engageable with a respective drive surface when the case transfer magazine is in the second position to raise and lower the comb shelf segments whereby the teeth of each comb shelf segment move from the one side to the other side of the teeth of an adjacent comb shelf of the case storage magazine for case transfer to or from the comb shelf segment.

7. The case handling and storage apparatus of claim 1 wherein each magazine comprises at least one pair of additional horizontal comb shelves, the teeth of each additional comb shelf of the case transfer magazine located between and to one side of the teeth on an adjacent additional comb shelf of the case storage magazine when the case transfer magazine is in the second position such that the teeth of adjacent comb shelves are vertically movable past each other for case transfer between the magazines.

8. The case handling and storage apparatus of claim 1 wherein the comb shelf connections of the case transfer magazine movably mount the support members to the frame of the case transfer magazine for vertical movement along the frame, the support members each being movable along the frame independently of one another whereby the comb shelves of the case transfer magazine are each independently movable between raised and lowered positions;

the drive surface of the case transfer magazine comprises a plurality of drive surfaces, each drive surface connected to a respective comb shelf support member for conjoint movement with the support member; and

the drive member of the second drive mechanism comprises a plurality of drive members, each drive member vertically movable independently of the other drive members, each drive member engageable with a respective drive surface whereby each comb shelf of the case transfer magazine can be selectively driven between raised and lowered positions for case transfer to or from the comb shelf.

9. The case handling and storage apparatus of claim 8, wherein the case transfer magazine comprises a plurality of vertical push rods, each push rod connected to a respective support member for conjoint vertical movement with the support member and extending from the support member to a free end, the drive surfaces located on the free ends of the push rods.

10. The case handling and storage apparatus of claim 8 wherein each support member of the case transfer magazine comprises a plurality of support segments spaced along the length of the comb shelf, a plurality of comb shelf teeth attached to each comb shelf segment to define a comb shelf segment for supporting a case;

each comb shelf connection of the case transfer magazine comprises a plurality of connection segments spaced along the length of the comb shelf, each connection segment movably mounting a respective support member segment for vertical movement along the frame whereby each comb shelf segment is movable between raised and lowered positions;

each support member segment is movable along the frame of the case transfer magazine independently of one another to raise or lower the comb shelf segments of the case transfer magazine independently of one another; and

the drive surfaces of the case transfer magazine are each connected to a respective support member segment for conjoint movement with the support member segment whereby each comb shelf segment of the case transfer magazine can be selectively driven between raised and lowered positions for case transfer to or from the comb shelf segment.

11. The case handling and storage apparatus of claim 10 wherein the case transfer magazine comprises a plurality of elongate push rods, each push rod connected to a respective support member segment for conjoint vertical movement with the support member segment and extending vertically from the support member segment to a free end below the frame of the case transfer magazine;

each of the drive surfaces of the case transfer magazine is a downwardly facing surface on the free end of a respective push rod;

the drive member of the second drive mechanism comprises a plurality of drive members located below the push rods;

the second drive mechanism comprises a plurality of actuators, each actuator connected to a respective drive member for moving the drive member horizontally between extended and retracted positions; and

each drive member is vertically aligned with a respective drive surface when the drive member is in the extended position such that the drive surface is in the path of vertical movement of the drive member, and the drive surface is out of the path of vertical movement of the drive member when the drive member is in the retracted position.

12. A case transfer apparatus for transferring cases to or from a case storage unit having a comb shelf comprising a plurality of spaced apart case support teeth, the case transfer apparatus comprising:

a frame;

an elongate, horizontal comb shelf extending across the frame for supporting a plurality of cases, the comb shelf including a plurality of comb shelf segments spaced along the length of the comb shelf, each comb shelf segment for supporting a case of the plurality of cases and comprising a support member, an operative connection movably mounting the support member to the frame for vertical movement on the frame, and a plurality of case-support teeth fixed to the support member and spaced apart along the support member, the teeth extending outwardly from the frame to free ends located away from the support member;

a plurality of actuation members, each actuation member connected to a comb shelf support member wherein movement of an actuation member moves a comb shelf segment vertically for case transfer; and

each support member being independently movable by the actuation member connected to such support member whereby only the teeth of the support members moved by actuation members pass between teeth of the comb shelf of the storage unit and participate in case transfer to or from the comb shelf of the case storage unit.

13. The case handling apparatus of claim 12, wherein:

each actuation member comprises a drive surface to receive a force moving the actuation member vertically;

the case handling apparatus further comprises a drive mechanism to move the actuation members for case transfer, the drive mechanism comprising a plurality of vertically movable drive members, each drive member engageable with the drive surface of a respective actuation member to drive the actuation member vertically to transfer a supported case to or from the comb shelf of the storage unit.

14. The case handling apparatus of claim 13, wherein each actuation member comprises an elongate push rod extending transversely to the comb shelf to a free end, the drive surface of the actuation member on the free end.

15. The case handling apparatus of claim 14 wherein the actuation members extend downwardly to free ends located below the comb shelf, each drive member located beneath the drive surface associated with such drive member.

16. The case handling apparatus of claim 15 comprising:

a transport vehicle for moving the frame to and from the storage unit, the vehicle comprising a chassis, the drive mechanism attached to and movable with the chassis;

the chassis comprising an upwardly facing support surface;

the frame comprising a downwardly facing support surface; and

the frame support surface engaging the chassis support surface whereby the frame is carried above the chassis.

17. The case handling apparatus of claim 16 wherein:

the drive mechanism comprises a lift table, a first drive to move the lift table above the chassis, and a plurality of second drives, each drive member driven by a respective second drive between extended and retracted positions;

the second drives are attached to the lift table for conjoint movement with the lift table wherein each drive member moves with the lift table along a vertical path; and

the drive surface associated with the drive member is in the path of the drive member when the drive member is in the extended position and the drive member is out of the path of the drive member when the drive member is in the retracted position.

18. The case handling apparatus of claim 12 wherein the comb shelf represents a first comb shelf and further comprising:

a second elongate, horizontal comb shelf on the frame for supporting a plurality of cases;

the second comb shelf extending across the frame and including a plurality of comb shelf segments spaced along the length of the comb shelf, each comb shelf segment for supporting a case of the plurality of cases and comprising a support member, an operative connection movably mounting the support member to the frame for vertical movement on the frame, and a plurality of case-support teeth fixed to the support member and spaced apart along the support member, the teeth extending outwardly from the frame to free ends located away from the support member;

a plurality of additional actuation members, each additional actuation member connected to a comb shelf support member of the second shelf wherein vertical movement of an additional actuation member moves a comb shelf segment of the second comb shelf vertically for case transfer; and

each support member of the second comb shelf being independently movable by the additional actuation member connected to such support member whereby only the support members of the second comb shelf moved by additional actuation members participate in case transfer to or from the second comb shelf.

19. The case handling apparatus of claim 18 wherein the first and second comb shelves are vertically spaced from one another, the comb shelf segments of the first comb shelf overlying corresponding comb shelf segments of the second comb shelf;

and

each actuation member and additional actuation member faces a comb shelf support member of the first comb shelf and a comb shelf support member of the corresponding second comb shelf.

20. The case handling apparatus of claim 18 wherein the first and second comb shelves are horizontally spaced from one another and the actuation members and additional actuation members are between the first and second comb shelf support members.

21. A case handling apparatus comprising:

a frame;

a normally horizontal comb shelf on the frame, the comb shelf being elongate and having opposed sides, said comb shelf including a plurality of teeth spaced apart along the comb shelf, said teeth extending across the comb shelf and having free ends on one side of the comb shelf;

a hinge on the other side of the comb shelf, the hinge connecting one tooth to the frame for rotation about a horizontal axis, the one tooth rotatable in a range of motion from a first position to a second position angularly displaced from the first position; and

a drive connected between the frame and the hinge to drive the one tooth to selectable positions between the first and second positions, the drive connected to the hinge throughout the range of motion of the one tooth.

22. The case handling apparatus of claim 21 wherein the first position of the tooth represents an extended position of the tooth and the second position represents a retracted position of the tooth, the tooth being substantially horizontal for supporting the case on the tooth when in the extended position and substantially vertical when in the retracted position for not participating in case transfer to or from the comb shelf.

23. The case handling apparatus of claim 21 wherein the first position of the tooth represents an extended position of the tooth and the second position represents a retracted position of the tooth, the tooth being substantial horizontal when in the extended position and the tooth sloping downwardly from the hinge to its own free end when in the discharge position for gravity discharge of a case supported on the tooth.

24. The case handling apparatus of claim 23 wherein the drive comprises a stop member movable between first and second positions, the stop member located in the path of the hinge to resist rotation of the tooth from the extended position to the discharge position when in the first position and the stop member out of the path of the hinge when in the second position.

25. The case handling apparatus of claim 24 wherein the hinge comprises a first portion connected to the first tooth and a second portion connecting a second tooth to the frame for rotation about the horizontal axis, the second hinge portion rotatable about the axis independently of the first hinge;

and

the case handling apparatus comprises a second drive connected between the frame and the second hinge portion to drive the second tooth to selectable positions about the axis independently of the position of the first tooth.

26. A method of transferring cases between case handling magazines, each case handling magazine having a plurality of spaced apart horizontal comb shelves, each comb shelf having a plurality of spaced apart case-support teeth, the method comprising the steps of:

loading a first case on a first comb shelf of a first magazine and loading a second case on a second comb shelf of the first magazine;

positioning the first magazine in a transfer relationship with a second magazine with the comb shelves of both magazines extending parallel to each other and each comb shelf of the first magazine adjacent to and above a corresponding comb shelf of the second magazine;

moving the first comb shelf of the first magazine vertically downward relative to the adjacent comb shelf of the second magazine to pass the teeth of the first comb shelf of the first magazine between the teeth of the adjacent comb shelf of the second magazine and position the first comb shelf of the first magazine below the adjacent comb shelf of the second magazine to transfer the first case from the first comb shelf of the first magazine to the adjacent comb shelf of the second magazine;

maintaining the second comb shelf of the first magazine above the adjacent comb shelf of the second magazine while moving the first comb shelf to retain the second case on the first magazine while transferring the first case; and

separating the magazines.

27. The method of claim 26 wherein the first comb shelf of the first magazine comprises a plurality of comb shelf segments, each comb shelf segment comprising a plurality of the first comb shelf teeth, the first case on a first comb shelf segment, the method comprising the steps of:

loading a third case on a second comb shelf segment of the first magazine; and

the moving step comprising the steps of;

moving the first comb shelf segment of the first magazine relatively downward relative to the adjacent comb shelf of the second magazine to pass the teeth of the first comb shelf segment between the teeth of the adjacent comb shelf of the second magazine and position the first comb shelf segment of the first magazine below the adjacent comb shelf of the second magazine to transfer the first case from the first comb shelf segment of the first magazine to the adjacent comb shelf of the second magazine; and

maintaining the second comb shelf segment of the first magazine above the adjacent comb shelf of the second magazine while moving the first comb shelf segment to retain the third case on the first magazine while transferring the first case.

28. The method of claim 27 wherein the case handling apparatus comprises a transport vehicle, the method comprising the steps of:

placing one of the first and second magazines on the transport vehicle away from the other magazine;

transporting the one magazine to the other magazine with the transport vehicle to position the magazines adjacent each other in the transfer relationship; and

taking the one magazine off of the transport vehicle.

29. The method of claim 28 wherein the transport vehicle includes a lift table, the method comprising the step of raising or lowering the lift table to move the first comb shelf of the first magazine vertically downward relative to the adjacent comb shelf of the second magazine.