DE102020128511A1 - Storage system for storing goods in a three-dimensional warehouse - Google Patents

Abstract

Storage system for storing and moving containers, comprising a three-dimensional lattice structure containing a large number of containers stacked vertically on top of one another, the lattice structure guiding a movement of at least one robotic vehicle in the X and/or Y direction; the robotic vehicle for storing and retrieving at least one container can be moved into or out of a stack in the X and/or Y direction within the lattice structure;wherein the storage system has at least one lifting device assigned to the lattice structure, which temporarily lifts the partial stack in order to enable access to the at least one container for the robotic vehicle.

Description

The invention relates to a storage system for storing goods in a three-dimensional warehouse according to claim 1.

It is known in the field of logistics to store articles or goods in warehouses, store them (or keep them) and retrieve them again. The bearings should allow the best possible use of space with high dynamics. Conventional bearings usually do not meet both requirements to the desired extent.

From the WO2016/172793 A1 it is known to arrange containers in vertical stacks within a grid structure surrounding vertically extending access shafts in which robotic vehicles can move up and down to manipulate the containers. In addition, the robot vehicles can move horizontally above or below the grid structure, as is known from the AutoStore system from the company Hatteland. With this system, a very high storage density and space utilization can be achieved. However, it has only a low level of dynamics, since the containers must first be transported all the way up or down to exchange or change their position and, if necessary, have to be rearranged within the stack for this purpose. The entire material flow runs over the top of the warehouse.

U.S. 2015/0127143 A1 discloses a similar system in which several stacked containers (partial stacks) can first be pulled up from above by a robotic vehicle on the lattice structure and then moved to the side in order to allow a second robotic vehicle, also from above on the lattice structure, to pick up the remaining containers that have been uncovered in this way To take container in the stack from above and pull separately up to then lower the partial stack again.

In contrast, the object of the present invention is to create an alternative storage system for storing goods in a three-dimensional warehouse which, in addition to high storage density, also has high dynamics.

This object is solved by the system given in claim 1. Advantageous configurations result from the dependent claims and the description.

According to the invention, the storage system for storing and moving containers comprises, similar to the prior art, a three-dimensional lattice structure containing a large number of containers stacked vertically, the lattice structure permitting a movement of at least one robot vehicle in the X and/or Y direction ( horizontal plane), but the robotic vehicle can be moved within the lattice structure for storing and retrieving at least one container in or from a stack in the X and/or Y direction. The storage system also has a lifting device assigned to the lattice structure, which temporarily raises the partial stack (in the Z direction or vertically) in order to enable access to the at least one container for the robotic vehicle.

In contrast to the state of the art, there is no container exchange via the top, but rather laterally through the stacked structure by means of vehicles (robot vehicles) designed for this purpose. A virtual/temporary aisle is thus created, which enables the vehicle to reach the desired container, although actually neighboring stacks of stacks block access due to the stacks arranged next to one another.

In order to enable the vehicles to access a desired container within the stacked assembly, all partial stacks arranged in the “neighboring” side of the desired container are lifted to the outside to create the virtual aisle, which is preferably closest to the desired container. so that the respective vehicle can take the shortest route from the outside to the desired container on the lattice structure in order to pick it up and transport it to the outside. In principle, a storage process takes place in the reverse order.

In one variant, the desired container itself can be uncovered by lifting all the containers above in its stack so that the vehicle can then pick it up (from the side). In another variant, the desired container is also raised and the vehicle drives under the raised partial stack or desired container. Only this is then specifically lowered onto the vehicle.

A plurality of stacks of containers arranged next to one another in both the X and Y directions are preferably arranged in the lattice structure.

The lifting and lowering of the partial stacks can take place "rolling" depending on the duration and distance to the desired container. In other words, a removed partial stack does not have to remain raised for the entire duration of the process, but can be lowered again in between. This creates a wave-like movement of the container part stacks, with the crest of the wave always being approximately above the vehicle. The virtual alley can therefore be dynamic in waves or standing be formed as an entire free aisle during storage or retrieval.

A single container is preferably stored or retrieved. However, two or more containers can also be stored or retrieved as small stacks at the same time.

Preferably, the lattice structure includes a plurality of upright supports extending in the Z direction and crossbeams extending in the X and Y directions for guiding the robotic vehicle in the X and Y directions, the supports and crossbeams surrounding the stacks of containers. The crossbeams are therefore not only a structural part of the lattice structure, but also serve as a rail for the robotic vehicles. Depending on the design of the robotic vehicles, it is possible to also supply the vehicles with power and/or signals or data via the crossbeams or travel rails.

The robotic vehicles themselves are designed to move within the lattice structure, preferably guided on and off the crossbeams as travel rails, for which purpose they have drive means compatible with the lattice structure. The robot vehicles can have an energy store (battery, power cap, etc.) to supply the drive and the internal control. External communication can take place via radio modules (Wlan, 5G etc.) or alternatively by means of conductor line-type collectors via the rail. The robotic vehicles can move autonomously via an internal control after accepting an order for storing or retrieving a specific container. For this purpose, they have suitable sensors such as laser scanners, etc. The actual driving commands are then given autonomously by the vehicle itself, possibly through swarm-like consultation and C2C communication. Central control is also conceivable.

It is also preferred if the at least one robotic vehicle is designed to pick up the at least one container.

To this end, as indicated above, it may have a recess for receiving a container within its periphery (container support recess). The recess is preferably open at the side.
Alternatively, the robotic vehicles can have a container carrying surface, preferably designed as the entire upper side of the vehicle, which is optionally additionally equipped with conveying means (belts, etc.).

The robotic vehicle is therefore adapted to the distances between the vertical supports and crossbeams specified by the lattice structure.

The robotic vehicle(s) travel(s) on the crossbeams by means of the drive means compatible with the lattice structure in the respective plane to the desired at least one container or stack. This can either be done linearly from the lift or in a zig-zag course with changes of direction, e.g. B. avoiding other robotic vehicles, avoiding traffic jams, etc.

So that the removed or stored containers can also be transported outside the lattice structure without breaking, it is preferable for the at least one robotic vehicle to have ground-accessible drive means, so that it can also transport the containers outside the lattice structure. For this purpose, the robotic vehicles can have AGV or AMR properties.

In a departure from the prior art, the lifting device associated with the lattice structure is not part of the robotic vehicle but part of the lattice structure. It can be provided for any vertical stack, i.e. permanently installed. Alternatively, the lifting device can also be moved, e.g. e.g. one lifting device per row, etc.

A gripping means of the respective lifting device is preferably arranged to be vertically movable within the space spanned by the upright supports in order to be positioned vertically along the stack on the respective container of the partial stack to be gripped.

In order to lift the (partial) container stack above the desired container in the lattice structure in order to make the desired container accessible, it can be provided that a gripping frame is arranged vertically movable within the upright supports of a stack as gripping means of the respective lifting device in order to Stack to be positioned along each to be taken lower container of the sub-stack.

In another variant, the gripping means can be designed to specifically lower the lowermost raised container of a (partial) stack onto the container carrying surface of a robotic vehicle positioned underneath. For this purpose, the gripping means can have a double gripping device, with each of the individual grippers of the gripping device being able to be at least lowered independently of one another by the lifting device.

The gripping means or gripping device can/can also be designed as vertical plate-shaped carriages with holding elements arranged on two opposite sides of a stack.

The gripping means is thus moved up and down vertically by the lifting device, but lies within the respective lattice structure. For this purpose, the gripping means can be moved by the lifting device by means of ropes (or other suitable means such as chains). Alternatively, the gripping means could also be moved via drive rollers or gears on the corresponding vertical supports.

In order to lift the partial stack from below, the gripping means grips the corresponding container of the (partial) stack and is equipped with holding elements that can be coupled and decoupled for optional interaction with the container (the lowest of the partial stack). This could e.g. B. be linearly extendable bolts or pivoting levers, etc. engage laterally in recesses or recessed edges of the container.

So that the robotic vehicles can reach the respective level of the lattice structure in which the desired container is to be collected or stored, at least one lift for robotic vehicles is preferably arranged outside the lattice structure on its outside. The robotic vehicle can thus enter the lift on the floor of a respective working level and be raised accordingly. One permanently installed lift can be provided for each row. Alternatively, a few movable lifts can also be provided on each outside, e.g. B. every 5 rows a lift.
The corresponding lifts can also be arranged within the lattice structure in corresponding free spaces in order to optimally shorten the longest path from the lift to the potential desired container. Then the working level z. B. can also be an intermediate level.

The lift is therefore designed to receive the respective robotic vehicle (including the container) and deliver it to the respective level or to provide an interface from the lift to the cross member for guiding the robotic vehicle.
In other words, the lift can be positioned and configured on at least one, preferably each, cross member level in order to allow the respective robotic vehicle access to the level.

Alternatively, ramps could also be provided or the robotic vehicles could automatically move up and down vertically on the outer structure of the lattice structure, e.g. B. from the WO 2019/232613 A1 famous.

The invention also relates to a method for operating a storage system in which access to a desired container is allowed in a controlled manner, for which purpose containers are temporarily moved away above and/or to the side, in particular raised upwards, so that a transport vehicle, e.g. B. a robotic vehicle, store the desired container or outsource.
In other words, the invention also relates to a method for operating a storage system in which a large number of containers stacked vertically on top of one another are stored within a three-dimensional lattice structure, characterized in that in order to allow access to a desired container, containers above and/or or temporarily moved away to the side of the desired container, in particular raised upwards.

The system may include a controller configured to coordinate the lifting units with one another. The control can be of a more traditional nature and can take place centrally, or also in the form of a decentralized control which is managed centrally but is designed as a swarm control.

In order to ensure a coordinated, synchronized process or movement of the cooperatively working lifting units, it is advantageous if the system allows synchronization and/or position determination of the lifting units, possibly with the aid of sensors, for example via markings on the supports. It is also conceivable to use height and acceleration sensors, such as are known from the field of mobile radios, which are inexpensive and small. The idea here is to coordinate and compare the positions of the interacting lifting units in order to enable the transport vehicles to access the desired container, for which purpose the sub-stacks of the containers are to be lifted and then lowered in a synchronized manner.

The system can be set up for a wireless exchange of information with the lifting units and/or transport vehicles. For this purpose z. g. WLAN, Bluetooth etc. Alternatively, communication can also take place via contact lines in the supports/crossbeams. Depending on the type of control, communication can take place directly between the paired lifting units and/or with the central warehouse control system (WMS) for the exchange of goods-specific storage commands.

In other words, the system according to the invention relates to an automated storage system with high density and high dynamics. It essentially comprises three or four components, namely the lattice structure, the lifting units and the transport vehicles and, if necessary, the lifts.

• 1 eine schematische perspektivische Ansicht eines Systems zum Lagern und Bewegen von Behältern;
• 2 eine weitere schematische perspektivische Ansicht auf das System der 1;
• 3 eine weitere schematische perspektivische Ansicht auf das System der 1;
• 4 eine perspektivische und vergrößerte Detailansicht eines Systems mit einer alternativen Ausgestaltung eines Roboterfahrzeugs;
• 5A, B eine perspektivische und vergrößerte Detailansicht der Fahrzeugliftanordnung aus 1 und
• 6 eine schematische Darstellung der wellenartigen Bewegung der Behälterstapel beim Auslagern eines Behälters

zeigen.Further details of the invention result from the following description of exemplary embodiments with reference to the drawing

• 1 a schematic perspective view of a system for storing and moving containers;
• 2 another schematic perspective view of the system of 1 ;
• 3 another schematic perspective view of the system of 1 ;
• 4 a perspective and enlarged detail view of a system with an alternative embodiment of a robotic vehicle;
• 5A, B a perspective and enlarged detail view of the vehicle lift assembly 1 and
• 6 a schematic representation of the wave-like movement of the container stack when retrieving a container

demonstrate.

A system for storing and moving containers in a three-dimensional warehouse, designated as a whole by 100, is shown in detail in the figures.

The system 100 relates to an automated storage system with high density and high dynamics, comprising a three-dimensional lattice structure 1 containing a large number of containers 3 stacked vertically one on top of the other in stacks 2.

The containers 3 are thus stacked directly one on top of the other, with a recessed lower edge of an upper container fittingly engaging in the corresponding opening of the container below. This prevents lateral slipping.

The lattice structure 1 has a plurality of upright supports 4 in the Z-direction and crossbeams 5 in the X- and Y-directions. The supports 4 and crossbeams 5 surround the stack 2 of the containers 3. The division or the spacing of the crossbeams is adapted to the height of the containers 3.

The system also includes at least one, but usually a large number of robotic vehicles 6 for storing and removing containers 3 in or from a stack 2, which can be moved within the lattice structure 1 in the X and Y directions for this purpose. The crossbeams 5 guide the robotic vehicles 6 in the X and Y directions during their movement and these as travel rails.

Each robotic vehicle 6 is designed to receive a container. those of 1 - 3 and 5 have to a container carrying recess 7, in which a container 3 can be received laterally. The robotic vehicles 6 can therefore be described as approximately U-shaped. The container carrying recess 7 includes movement means, not shown, for grasping and drawing in or dispensing a container.

The robotic vehicles 6* of 4 on the other hand, have a container carrying surface 7*. The container carrying surface 7* is designed as the entire upper side of the vehicle and is additionally equipped with conveyor belts 7*F, via which the container can be released.

It goes without saying that the robotic vehicles could also pick up two stacked containers at the same time (cf. above).

The robotic vehicles 6 (and 6*) have, on the one hand, drive means 8A, B compatible with the lattice structure, with which they can drive autonomously on the crossbeams 5 to the desired container 3. These can be classic running wheels 8A analogous to shuttle technology, as in the case of the robot vehicle 6, or a more caterpillar-like drive 8B, as in the case of the robot vehicle 6*.

So that the container 3 does not have to be handed over, but can be transported throughout the system by a robotic vehicle 6, the robotic vehicles 6 (and 6*) also have ground-going drive means 9 in order to move them in AMR or AGV fashion on the floor of a working level 10 to drive. Depending on suitability, these can be the same drive means as in the lattice structure or additional ones.

In the 1 - 3 one can see that the bearing or the lattice structure 1 also extends further below the working plane 10 . So this is an intermediate level.

The storage system 100 also has at least one lifting device 11 assigned to the lattice structure 1 . This lifts partial stacks temporarily in order to allow access to the at least one container 3 for the robotic vehicle 6 . In the present case, each stack 2 is assigned a lifting device 11 arranged on the upper side of the lattice structure 1 and permanently installed there. In the 1 - 3 this is not shown to improve clarity and in 5 only indicated as winch drums.

Each lifting device 11 comprises a gripping means 12 arranged to be vertically movable within the space spanned by the upright supports 4 in order to be positioned vertically on the stack 2 along the respective lower container 3 of the sub-stack to be gripped. For this purpose, the gripping means 12 is equipped with holding elements 14 that can be coupled in and out for selective interaction with the container 3 . That respective gripping means 12 is moved up and down from above via steel cables 13 .

The gripping means 12 can be a gripping frame 12a (see FIG 5 ) or two gripping slides 12b ( 4 , only one visible).

The gripping frame 12a after 5 is arranged to be vertically movable within the space between the uprights 1 of a stack 2 to be positioned surrounding and along the stack 2 towards the respective bottom container 3 of a sub-stack to be gripped. This variant is preferably used when the robotic vehicles are designed with a container carrying recess 7, ie accommodate the desired container laterally.

In the other variant ( 4 ) the gripping means 12b is designed as a vertical plate-shaped carriage 13 arranged on two opposite sides of a stack. It is also designed to specifically lower the lowermost raised container of a (partial) stack onto the container-carrying surface 7* of a robotic vehicle 6* positioned underneath. For this purpose, the gripping means 12b has a double gripping device, with each of the individual grippers of the gripping device being able to be at least lowered independently of one another by the lifting device 11.

The system 100 also includes a plurality of lifts 15 for raising and lowering the robotic vehicles 6. In the present case, the lifts are only arranged on the outside of the lattice structure 1. Each lift 15 or its lifting platform 16 can be positioned and configured on at least one cross member level in order to allow the respective robotic vehicle 6 access to the level in the lattice structure 1 . For this purpose, the respective robotic vehicle 6 can drive into the lifting platform 16 lowered onto the working plane 10 and is then raised by it.
Arriving at the desired cross member level 17, the lifting platform 16 can be arranged flush with the cross members 5 serving as travel rails, so that the robotic vehicle 6 can drive into the virtual aisle. Elevator 15 can wait to return or work on other tasks in the meantime.

The lifts 15 also extend through the working level 10 downwards along the height of the entire lattice structure 1. Thus, the robotic vehicles 6 can also use other working levels, such as e.g. B. Approach delivery levels and delivery levels.

It is also understood that the system 100 includes a central warehouse controller (WMS), not shown, and is also set up for wireless information exchange with the lifting units and transport vehicles.

For this purpose z. B. WLAN, Bluetooth, etc. Depending on the type of control and necessity, communication can take place directly between the lifting devices and robotic vehicles and/or with the central warehouse control system (WMS) for the exchange of container-specific storage commands.

6 illustrates the wave-like, temporary and vertical movement of the container stack 2 when retrieving a desired container 3*, only the container 3* itself being indicated for illustration purposes. It goes without saying that the same processes apply analogously to storage.

In the starting position (A), all the stacks 2 of the containers 3 are arranged in their closest packing.

If the container 3* is now to be removed from storage, the adjacent containers 3 or their stacks 2 must make room, i. H. be lifted upwards to create a virtual lane so that a robotic vehicle 6 can enter the corresponding level of the lattice structure 1, which has been brought to level 17 via the corresponding lift to collect the container 3*.

For this purpose, the gripping means 12 are correspondingly lowered via the respective lifting devices 11 along the path of the virtual lane and the respective partial stack is raised after the holding elements 14 have been activated (cf. B).

As in 6 indicated, this lifting can be temporary in such a way that only those partial stacks in the area where the robotic vehicle 6 or container 3* is actually located are lifted. The others behind or in front of it (along the virtual lane) are lowered again or not yet raised.

This is how the wave-like pattern that wanders in (C) in the stylized side view is created.

Alternatively, it would also be possible to leave all partial stacks of the virtual aisle raised until the robotic vehicle 6 enters and exits again.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• WO 2016/172793 A1 [0003]
• US 2015/0127143 A1 [0004]
• WO 2019/232613 A1 [0030]

Claims (11)

Storage system for storing and moving containers, comprising a three-dimensional lattice structure containing a multiplicity of containers stacked vertically on top of one another, the lattice structure guiding a movement of at least one robot vehicle in the X and/or Y direction; the robotic vehicle can be moved in the X and/or Y direction within the lattice structure for storing and removing at least one container from a stack; wherein the storage system has at least one lifting device assigned to the lattice structure, which lifts the partial stack temporarily in order to enable access to the at least one container for the robotic vehicle. system after claim 1 , characterized in that the lattice structure has a plurality of upright supports in the Z direction and crossbeams in the X and/or Y direction for guiding the robotic vehicle in the X and/or Y direction, the supports and crossbeams supporting the stacks of surround containers. system after claim 1 or 2 , characterized in that the at least one robotic vehicle is designed to receive the at least one container. system after claim 3 , characterized in that the at least one robotic vehicle has a container carrying surface or container carrying recess. System according to one of the preceding claims, characterized in that the at least one robotic vehicle also has ground-based drive means in addition to drive means which can be used in the lattice structure. System according to one of the preceding claims, characterized in that a lifting device can be positioned above each stack or is permanently installed. system after claim 6 , characterized in that within the space spanned by the upright supports a gripping means of the respective lifting device is arranged to be vertically movable in order to be positioned vertically along the stack at the respective lower container of the sub-stack to be gripped. system after claim 7 , characterized in that the gripping means is equipped with holding elements that can be coupled and decoupled for optional interaction with a container. System according to one of the preceding claims, characterized in that at least one lift for robotic vehicles is arranged outside or inside the lattice structure. system after claim 9 , characterized in that the lift can be positioned on at least one cross member level and is designed to allow the respective robotic vehicle access to the level. Method for operating a storage system, in particular according to one of the preceding claims, in which a large number of containers stacked vertically one on top of the other in stacks is stored within a three-dimensional grid structure, characterized in that in order to allow access to a desired container, containers above and/or temporarily moved away to the side of the desired container, in particular raised upwards.

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