Automated 3-dimensional multitasking, stocking, storage, and distribution system

• US 7,381,022 B1
• Filed: 12/18/2004
• Issued: 06/03/2008
• Est. Priority Date: 12/18/2004
• Status: Expired due to Fees

• Current Assignee: Rodney Joe King
• Original Assignee: Rodney Joe King
• Inventors: King, Rodney Joe
• Primary Examiner(s): KEENAN, JAMES W
• Application Number:
  US11/018,497
• Time in Patent Office: 1,263 Days
• Field of Search: 414/267, 414/279, 414/807, 187/270
• US Class Current: 414/267
• CPC Class Codes: B65G 1/0492 with cars adapted to travel in storage aisles
• CPC Class Codes: B65G 1/1375 the orders being assembled on a commissioning stacker-crane or truck

Abstract

An automated storage and retrieval system wherein electrically driven, computer-controlled carriages (58) can navigate a system of rails (78) in three-dimensions. Multiple carriages (58) can independently operate at the same time to accomplish a task faster or to work on several different tasks at the same time. The rails (78) have a system of trap doors (95) that allow a carriage (58) to use a single reversible motor (67) to navigate the rails (78) in three-dimensions. With the carriage (58) in positioned in font of a bin position, the carriage mounted manipulating device (125) can move bins (115) to and from the racks (107) from either side with a single reversible motor (131). The rails (78) are electrified to provide power for the drive (67) and manipulator motors (131). A main computer (146) maintains the inventory, handles transactions and assigns tasks to the computer-controlled carriages (58). The system can be scaled to handle different types of items and can be configured to fit in the space available.

Claims

1. An automated 3-dimensional multitasking, product stocking, storage and distributing system comprising:

a) a system of rails comprising;

i) a plurality of horizontal rails running in the x-direction and a plurality of vertical rails running in the y-direction,

ii) said rails have a plurality of notches to provide a means for meshing with toothed rotational devices,

iii) said rails are paired and mounted to allow open spaces between said rails,

iv) said horizontal rails running in the x-direction are interrupted along their length by a plurality of trapdoors,

v) said trapdoors have a hinge mechanism on one side and are torsion mounted to be normally in the open position,

vi) said trapdoors close when toothed rotational devices roll onto said trapdoors from said hinged side,

vii) said trapdoors when closed, complete said horizontal rails running in the x-direction, preventing access to said vertical rails running in the y-direction,

viii) when said toothed rotational devices roll into said trapdoors from the open side, said trapdoors guide said toothed rotational devices onto said vertical rails running in the y-direction,

ix) when said toothed rotational devices reverse direction of rotation on said vertical rails running in the y-direction, the said trapdoors guide said toothed rotational devices back onto said horizontal rails running in the x-direction,

whereby access to and from said horizontal rails running in the x-direction, to and from said vertical rails running in the y-direction is facilitated,

b) a plurality of carriages, each of said carriages comprising;

i) a frame of dimensions to fit between pairs of said rails,

ii) a drive motor mounted on said frame for producing rotational energy from said drive motor,

iii) a plurality of the toothed rotational devices,

iv) a means for controllably coupling rotational energy from said drive motor to said toothed rotational devices,

whereby said carriage can be propelled along said horizontal rail,

v) a plurality of rail guides are mounted fore and aft of said toothed rotational devices, said rail guides engage said vertical rails running in the y-direction to provide a means to hold said toothed rotational devices meshed with said vertical rails running in the y-direction,

whereby said carriages can be propelled up and down said vertical rails running in the y-direction,

vi) a braking system to hold said carriages in place when operating on said vertical rails running in the y-direction,

vii) a sensor to indicate location of said carriages on said system of rails,

viii) a control device to receive instructions and act in concert with said sensor to provide a means to control said carriages,

whereby said carriages will be self propelled and self controlled along said system of rails.

2. An automated system as set forth in claim 1 wherein said carriages and rail system includes:

a) a plurality of horizontal rails running in the z-direction, perpendicular to said horizontal rails running in the x-direction,

i) said horizontal rails running in the z-direction rails are positioned under predetermined lengths of the vertical rails running in the z-direction,

whereby said carriage can be lowered from said horizontal rails running in the x-direction to said horizontal rails running in the z-direction,

whereby said carriages change direction of travel on the horizontal plane,

ii) said horizontal rails running in the z-direction having the same said notches and trapdoors as the said horizontal rails running in the x-direction,

iii) a predetermined bend changes the slope of said horizontal rails running in the z-direction allowing the end of said horizontal rails running in the z-direction to have sufficient elevation to facilitate said carriages to be lowered through said trapdoors onto said vertical rails running in the y-direction, said carriage is lowered onto said rails running in the x-direction,

b) a second set of toothed rotational devices are mounted to said carriages'"'"' frames,

i) said second set of toothed rotational devices are arranged perpendicular to said toothed rotational devices,

ii) said second set of toothed rotational devices provide the same means of motion in the z-direction and the y-direction, as said toothed rotational devices, provided in the x-direction and the y-direction,

whereby said carriages on said rails can travel in three-dimensions.

3. The automated system of claim 2 wherein a bin manipulator is mounted to each of said carriages'"'"' said bin manipulators are each comprised of:

a) a framework for transporting bins,

b) said bins comprising;

i) enclosures of a predetermined shape to hold what is to be transported,

ii) lips for said container to slide on while being manipulated and rest on while said bins, are being transported,

c) a manipulator means, comprising;

i) a plurality of hitches to provide a means for manipulator arms to engage said bins by said hitches,

ii) a manipulator motor mounted on said frame for producing rotational energy from said manipulator motor,

iii) a means for controllably coupling rotational energy from said manipulator motor to said manipulator arm,

whereby said manipulator arm can extend to said hitches and pull said bins into said framework for transporting or push said bins out of said framework for transporting.

4. The automated system of claim 3, further including a system of racks, comprising:

a) a plurality of vertical support structures,

b) said vertical support structures support a plurality of horizontal support surfaces,

d) said horizontal support surfaces serve to support said bins

e) a plurality of access panels, comprising;

i) a plurality of customer interface devices to facilitate transactions,

ii) a plurality of delivery access panels to facilitate delivery and removal of items from said bins,

f) a loading access panel to allow items to be loaded into bins.

5. The automated system of claim 4, further including an enclosure, said enclosure constructed to provide structure, protection, insulation environmental control and security.

6. The automated system of claim 5 wherein said rails are electrified to supply electrical power for said drive motor, manipulator motor and control device.

7. The automated system of claim 6 further including an electronic control system, said electronic control system provides a human interface, said human interface facilitates instructions and is used to resolve problems.

8. The automated system of claim 7, further including a means to deliver items to customers, comprising:

a) an inner and outer door, to allow access to said bins,

b) an interlock, said interlock prevents said inner and outer door from being open at the same time,

whereby exposure to said electrified parts is prevented,

c) an imaging device, said imaging device records an image of said bins.