JP7793663B2 - Delivery vehicle, automated warehouse system, and method for transporting storage containers between an automated warehouse grid and a second location - Google Patents

Description

The present invention relates to a remotely operated delivery vehicle for transporting storage containers between an automated storage grid and a second location for handling the storage containers by at least one of a robotic operator and a human operator. The present invention also relates to an automated storage and retrieval system including the automated storage grid and a delivery system, and a method for transporting storage containers between the automated storage grid and the second location.

Figures 1A and 1C disclose a typical prior art automated warehouse system 1 having a framework structure 100. Figures 1B and 1D disclose a prior art container handling vehicle 101 that operates the system 1 disclosed in Figures 1A and 1C, respectively.

The framework structure 100 includes a plurality of upright members 102 and, optionally, a plurality of horizontal members 103 that support the upright members 102. The members 102, 103 may typically be made from metal, for example, from extruded aluminum profiles.

The framework structure 100 defines a storage grid 104, which includes storage columns 105 arranged in rows, within which storage containers 106 (also known as bins) are stacked one on top of the other to form stacks 107.

Each storage container 106 is typically capable of holding multiple product items (not shown), and the product items within a storage container 106 may be identical or may be of different product types depending on the application.

The storage grid 104 prevents horizontal movement of the storage containers 106 within the stack 107 and guides vertical movement of the storage containers 106, but typically does not otherwise support the storage containers 106 when stacked.

The automated warehouse system 1 includes a container handling vehicle rail system 108 arranged in a grid pattern across the top of the storage grid 104, and a plurality of container handling vehicles 200, 300 (as illustrated in Figures 1B and 1D) operate on the rail system 108 to raise storage containers 106 from, lower storage containers 106 into, and transport storage containers 106 up the storage columns 105. The horizontal extent of one of the grid cells 122 that make up the grid pattern is marked by a bold line in Figures 1A and 1C.

Each grid cell 122 has a width that is typically in intervals of 30 cm to 150 cm and a length that is typically in intervals of 50 cm to 200 cm. Each grid opening 115 has a width and length that are typically 2 cm to 10 cm smaller than the width and length of the grid cell 122 due to the horizontal extent of the rails 110, 111.

The rail system 108 includes a first set of parallel rails 110 and a second set of parallel rails 111, the first set of parallel rails 110 arranged to guide movement of the container handling vehicles 200, 300 in a first direction X across the top of the frame structure 100, and the second set of parallel rails 111 arranged perpendicular to the first set of rails 110 and guiding movement of the container handling vehicles 200, 300 in a second direction Y that is perpendicular to the first direction X. The rail system 108 thus defines a grid column above which the container handling vehicles 200, 300 can move laterally above the storage columns 105, i.e., in a plane that is parallel to the horizontal X-Y plane.

Each prior art container handling vehicle 200, 300 includes a vehicle body and a wheel structure 201, 301 of eight wheels, with a first set of four wheels allowing lateral movement of the container handling vehicle 200, 300 in the X direction and a second set of four wheels allowing lateral movement in the Y direction. One or both sets of wheels in the wheel structure can be lifted and lowered so that the first set of wheels and/or the second set of wheels can be engaged with the respective set of rails 110, 111 at any one time.

Each prior art container handling vehicle 200, 300 also includes a lifting device (not shown) for vertical transportation of the storage container 106, e.g., for raising the storage container 106 from the storage column 105 and lowering the storage container 106 into the storage column 105. The lifting device includes one or more gripping/engagement devices (not shown) adapted to engage the storage container 106, such that the gripping/engagement devices can be lowered from the vehicle 201, 301 and the position of the gripping/engagement devices relative to the vehicle 201, 301 can be adjusted in a third direction Z, the third direction Z being perpendicular to the first direction X and the second direction Y.

Conventionally, and for purposes of this application, Z=1 identifies the top layer of the grid 104, i.e., the layer immediately below the rail system 108; Z=2 identifies the second layer below the rail system 108; Z=3 identifies the third layer, and so on. In the exemplary prior art grid 104 disclosed in FIGS. 1A and 1C, Z=8 identifies the bottom layer at the bottom of the grid 104. Consequently, by way of example and using the Cartesian coordinate system X, Y, Z shown in FIGS. 1A and 1D, a storage container identified as 106' in FIG. 1A may be said to occupy grid location or cell X=10, Y=2, Z=3. A container handling vehicle 101 may be said to travel in layer Z=0, and each grid column may be identified by its X and Y coordinates.

Each container handling vehicle 200 includes a storage compartment or space (not shown) for receiving and storing the storage containers 106 as they are transported across the rail system 108. The storage space may include, for example, a cavity centrally located within the vehicle body, as described in WO 2014/090684 A1, the contents of which are incorporated herein by reference.

Alternatively, the container handling vehicle 300 may have a cantilever beam structure, as described in NO 317366, the contents of which are also incorporated herein by reference.

The container handling vehicle 200 may have a predetermined footprint, i.e., extent in the X and Y directions, that is generally equal to the lateral extent of a grid cell 122, i.e., generally equal to the extent of a grid cell 122 in the X and Y directions, as described, for example, in WO 2015/193278 A1, the contents of which are incorporated herein by reference. As used herein, the term "lateral" may mean "horizontal."

Alternatively, the container handling vehicle 200 may have a footprint that is larger than the lateral extent of the grid column 105 (the lateral area defined by the grid column 105), as disclosed, for example, in WO 2014/090684 A1.

The rail system 108 can be a single track system, as shown in Figure 2A. Alternatively, the rail system 108 can be a double track system, as shown in Figure 2B, thus allowing a container handling vehicle 201 having a footprint 202, 202' generally corresponding to the lateral area defined by the grid columns 112 to travel along a row of grid columns (even when another container handling vehicle 200 is positioned above a neighboring grid column in that row). Both the single-track system and the double-track system, or a combination including single-track and double-track configurations in the single-rail system 108, form a grid pattern in the horizontal plane P including a plurality of rectangular and uniform grid locations or grid cells 122, where each grid cell 122 includes a grid opening 115 bounded by a pair of rails 110a, 110b of the first rail 110 and a pair of rails 111a, 111b of the second set of rails 111. In FIG. 2B, the grid cells 122 are indicated by dashed boxes.

As a result, rails 110a and 110b form a pair of neighboring rails that define parallel rows of grid cells running in the X direction, and rails 111a and 111b form a pair of neighboring rails that define parallel rows of grid cells running in the Y direction.

2C, each grid cell 122 has a width _Wc that is typically in the interval of 30 cm to 150 cm and a length _Lc that is typically in the interval of 50 cm to 200 cm. Each grid opening 115 has a width _Wo and a length _Lo that are typically 2 cm to 10 cm smaller than the width _Wc and length _Lc of the grid cell 122.

In the X and Y directions, neighboring grid cells 122 are positioned in contact with each other so that there is no space between them.
Within the storage grid 104, the majority of the grid columns are storage columns 105, i.e., grid columns 105 in which storage containers 106 are stored in stacks 107. However, the grid 104 typically has at least one grid column that is not used to store storage containers 106, and that at least one grid column includes a location where a container handling vehicle 200, 300 can drop off and/or pick up a storage container 106 so that the storage container 106 can be transported to a second location (not shown) where the storage container 106 can be accessed from outside the grid 104 or transferred out of or into the grid 104. In the art, such locations are typically referred to as "ports," and the grid columns in which the ports are located may be referred to as "delivery columns" 119, 120. The drop-off and pickup ports for the container handling vehicles are referred to as the "upper ports of the delivery column" 119, 120. The opposite end of the delivery column is referred to as the "lower port of the delivery column."

1A and 1C includes two distribution columns 119 and 120. The first distribution column 119 may, for example, include a dedicated drop-off port where container handling vehicles 200, 300 can drop off storage containers 106 for transport through the distribution column 119 and further to an access station or transfer station (not shown), and the second distribution column 120 may include a dedicated pickup port where container handling vehicles 200, 300 can pick up storage containers 106 that have been transported through the distribution column 120 from the access station or transfer station (not shown). Each of the ports of the first and second distribution columns 119, 120 may include ports suitable for both pickup and drop-off of storage containers 106.

The second location may typically be a picking or stocking station where product items are removed from or positioned into the storage containers 106. At the picking or stocking station, the storage containers 106 are typically never removed from the automated warehouse system 1, but rather are accessed and placed back into the storage grid 104. There are also lower ports provided in the delivery column for the transfer of storage containers out of or into the storage grid 104, such as for transferring the storage containers 106 to another storage facility (e.g., to another storage grid), directly to a transport vehicle (e.g., a train or lorry), or to a production facility.

To monitor and control the automated storage system 1 (e.g., to monitor and control the location of each storage container 106 within the storage grid 104; the contents of each storage container 106; and the movements of the container handling vehicles 200, 300 so that the desired storage containers 106 may be delivered to the desired locations at the desired times without the container handling vehicles 200, 300 colliding with each other), the automated storage system 1 includes a control system (not shown), which is typically computerized and which typically includes a database for tracking the storage containers 106.

A conveyor system including conveyors may be used to transport storage containers between the lower ports of the delivery columns 119, 120 and the access stations.
If the lower ports and access stations of the delivery columns 119, 120 are located at different levels, the conveyor system may include a lift device for transporting the storage containers 106 vertically between the ports and the access stations.

The conveyor system may be arranged to transfer storage containers between different grids, for example as described in WO 2014/075937 A1, the contents of which are incorporated herein by reference.

Furthermore, WO 2016/198467 A1 (the contents of which are incorporated herein by reference) discloses an example of a prior art access system having a conveyor belt (Figures 5a and 5b in WO 2016/198467 A1) and frame-mounted rails (Figures 6a and 6b in WO 2016/198467 A1) for transporting storage containers between a delivery column and a workstation where an operator can access the storage containers.

When a storage container 106 stored in the grid 104 disclosed in FIG. 1A is to be accessed, one of the container handling vehicles 200, 300 is directed to retrieve the target storage container 106 from its location in the grid 104 and transport the target storage container 106 to or through the delivery column 119. This action involves moving the container handling vehicle 200, 300 to a grid location above the storage column 105 in which the target storage container 106 is positioned, using a lifting device (not shown) on the container handling vehicle to retrieve the storage container 106 from the storage column 105, and transporting the storage container 106 to the delivery column 119. If the target storage container 106 is positioned deep within the stack 107, i.e., if one or more other storage containers are positioned above the target storage container 106, the operation also involves temporarily moving the storage containers positioned above before lifting the target storage container 106 from the storage column 105. This step, which may be referred to in the art as “digging,” may be performed by the same container handling vehicle 200, 300 subsequently used to transport the target storage container 106 to the delivery column, or may be performed by one or more other cooperating container handling vehicles 200, 300. Alternatively or additionally, the automated warehouse system 1 may have container handling vehicles 200, 300 specifically specialized for the task of temporarily removing the storage container 106 from the storage column 105. Once the target storage container 106 has been removed from the storage column 105, the temporarily removed storage container may be repositioned back into the original storage column 105. However, the removed storage container may alternatively be repositioned in another storage column 105.

When a storage container 106 is to be stored in a grid 104, one of the container handling vehicles 200, 300 is directed to pick up the storage container 106 from the delivery column 120 and transport the storage container 106 to the grid location above the storage column 105 where it will be stored. After any storage containers positioned at or above the target location in the storage column stack 107 are removed, the container handling vehicle 200, 300 positions the storage container 106 in the desired location. The removed storage container can then be lowered back into the storage column 105 or repositioned in another storage column 105.

A problem associated with known automated storage systems 1 is that the areas surrounding the pickup and drop-off ports can become congested with container handling vehicles 200, 300 directed to drop off or pick up storage containers 106. This can seriously hinder the operation of the automated storage system 1. In smaller systems, this situation can sometimes be alleviated by adding delivery columns to the grid, as this allows the container handling vehicles 200, 300 to be distributed among a greater number of delivery column ports to avoid congestion. However, when ports and columns are added, the conveyor system infrastructure must typically be increased. This requires space, which may not always be available. Also, adding conveyor system infrastructure is costly.

Another problem with the prior art automated warehouse system 1 is that the separate drop-off and pickup ports of the delivery columns 119, 120 require the container handling vehicles 200, 300 to travel to the storage column 105 after drop-off to retrieve new storage containers 106. Similarly, the container handling vehicles 200, 300 must be free of storage containers 106 when they are sent to the pickup port 120 to pick up storage containers. This results in inefficiencies and causes increased congestion around the ports because the container handling vehicles 200, 300 are moving around on the grid without storage containers 106 as payload. Additionally, the delivery columns 119, 120 may occupy space above the grid 104 that could be used for other purposes, such as the movement of container handling vehicles 200, 300.

In view of the above, it would be desirable to provide an automated warehouse system, and a method for operating such a system, that overcomes or at least mitigates one or more of the above-mentioned problems associated with the use of prior art warehouse systems.

The object of the present invention is to provide an automated storage system that is more effective than prior art systems by avoiding or at least reducing congestion of storage containers around delivery columns.

Another object is to provide an automated warehouse system that improves the availability of delivery columns for container handling vehicles operating on a rail system.
Yet another object is to provide a highly efficient automated warehouse system that is easy to install and whose delivery capacity can be easily increased after installation is complete.

A further object is to provide an automated warehouse system that improves efficiency and expedites the storing and retrieving of items in storage containers.

The invention is set out in the independent claims, while the dependent claims describe alternatives to the invention.
In one aspect, the invention relates to a remotely operated delivery vehicle for transporting storage containers between an automated warehouse grid configured to store a plurality of stacks of storage containers and a second location, the second location being for handling the storage containers by at least one of a robotic operator and a human operator, e.g., for handling items in the storage containers.

Remotely controlled delivery vehicles
a rolling device configured to move the remotely operated vehicle in a horizontal plane;
a rolling device motor for driving the rolling device;
a power source configured to provide propulsive power to the rolling device motor.

The remotely operated delivery vehicle may further include a container carrier configured to receive a storage container from above and on or at least partially within the container carrier, such that contents of the storage container are accessible by at least one of a robotic operator and a human operator.

The rolling device may be configured to move a remotely operated delivery vehicle along the tracks of a delivery rail system, the delivery rail system including one set of parallel rails and a second set of parallel rails, the one set of parallel rails being arranged in a horizontal plane (P1) and extending in a first direction (X), and the second set of parallel rails being arranged in the horizontal plane (P1) and extending in a second direction (Y) perpendicular to the first direction (X).

The rolling device may be connected to a vehicle body or vehicle base located below the container carrier. The container carrier may be connected directly to the vehicle body and/or may be connected to the body via a structure. In all cases, the container carrier will be located above the vehicle body of the delivery vehicle.

In yet another exemplary configuration, the container carrier and vehicle body may be provided in one unit.
In the following, the term "remotely operated delivery vehicle" will be referred to as "delivery vehicle", the term "automated warehouse grid" will be referred to as "storage grid", and the term "storage container" will also be known in the prior art as "bin".

The container carrier may advantageously be adapted so that it can receive storage containers from directly above the delivery vehicle, from the side of the delivery vehicle, or a combination thereof.

In a preferred embodiment, the container carrier is adapted to receive a storage container from a delivery column of a warehouse grid when the delivery vehicle is positioned directly beneath the delivery column.

The delivery vehicle may include a vehicle body including one or more compartments for storing a power storage source, such as a battery. The compartments may also be adapted to store components, such as a rail-shift motor, a tilt motor, an actuator, a controller, etc. A rolling device (e.g., a wheel or drive belt) may be connected to the vehicle body and operated by an electric motor. The electric motor may be, for example, at least partially disposed within the rolling device, such as a hub motor. Furthermore, the electric motor may include permanent magnets, such as a brushless electric DC (direct current) motor. For example, the electric motor may include a rotor including one or more permanent magnets and a stator in the form of electrical windings wound around a yoke. An electric motor including a stator magnet and a rotor yoke/winding is also contemplated. An AC motor is also a possibility.

The vehicle body may be a framework similar to that disclosed in WO 2016/120075 A1 (hereby incorporated by reference), but without a cavity configured to store the storage container therein. The vehicle body may have a height that substantially corresponds to the diameter of the rolling device.

In operation, the delivery vehicle can be operated so that it is positioned directly or substantially directly below a delivery port of a delivery column of the automated warehouse grid, such that it can receive a storage container into it from above its container carrier.

Due to the above-described rolling device and associated rolling device motor and power source, the delivery vehicle may be adapted for self-propelled movement to the second location, which may include a robotic vehicle.

The delivery vehicle is capable of receiving storage containers onto or into the container carrier from a conveyor belt or other delivery system capable of transporting storage containers. In this particular embodiment, the storage containers may be slid or lifted onto the container carrier from at least one side of the delivery vehicle.

Distribution columns may be referred to as grid columns, which are used to transport storage containers through them and are therefore devoid of storage containers. Thus, a storage grid may include storage grid locations where container handling vehicles can drop off and/or pick up storage containers for onward transport to/from a desired storage column. Distribution columns may be located at any desired location within the storage grid, but are preferably located at or near the periphery of the storage grid.

A delivery column may include a pickup or drop-off port located at an upper level of the storage grid (i.e., the level where the container handling vehicles operate) and a delivery port located at a lower level/end of the storage grid. At the lower level/delivery port, storage containers may be inserted into or removed from the delivery column, for example, with the assistance of a delivery vehicle.

A shipping port can be an opening located at the lowest position of a shipping column that allows for the pick-up and/or drop-off of storage containers.
The storage containers may be transported through the distribution column by lifting means, for example in the form of lifting devices of the prior art container handling vehicles mentioned above.

Alternatively, the lifting means may be a dedicated lift configured to transport storage containers through the delivery column, such as the lift disclosed in patent publication WO 2017/121515 A1 (hereby incorporated by reference).

In one exemplary configuration, storage containers may be transported in a loop between a delivery port and a predetermined second location. In this manner, any storage container may be retrieved through the same delivery column in which it was deposited or through any other delivery column configured for the same purpose.

The loop can contain multiple circulating storage containers, thereby reducing or avoiding congestion on the rail system on one or more lateral sides of the delivery column.

A container handling vehicle deposits a storage container in a delivery column and then picks up a new storage container for delivery to or retrieval from the same delivery column.

The remotely operated delivery vehicle may be configured to receive storage containers from a delivery port of the storage grid for transport to a second location, where the storage containers and/or the product items in the respective storage containers may be handled. Additionally, the delivery vehicle may be configured to transport the storage containers from the second location for delivery to the delivery port. In both cases, the storage containers may be transported through the storage grid via the delivery columns by a lifting means/lifting device.

The second location can be any predetermined location suitable for handling storage containers by at least one of a robotic operator and a human operator, for example, acting as a picking or stocking station where product items are removed from or placed into storage containers. The second location may be remote from the storage system.

The robotic or human operators can be, for example, pickers provided to handle goods/items in containers. Pickers may pick items from containers, refill items into containers, or they may handle entire storage containers by replacing, removing, and/or inserting containers into the storage grid.

Furthermore, the second location can be any predetermined location that allows the storage container to be accessed from a location outside the storage grid and/or a location associated with the storage grid.

The second location may be physically connected to the storage grid and/or remain connected to the storage grid. The delivery vehicle operates independently between the delivery port and the second location.

Generally, the second location can be any predetermined location reachable by the delivery vehicle when operating on the delivery rail system. The delivery rail system can be disposed between the second location and one or more delivery ports of the storage grid. In this manner, storage containers can be transported on the delivery vehicle between the delivery port and the second location without requiring costly and/or inefficient infrastructure (e.g., conveyor belts, etc.) and/or without requiring human/robotic intervention. As described above, transport can occur on the delivery vehicle's container carrier. Furthermore, each delivery vehicle can move independently in the X and Y directions along the delivery rail system.

The delivery rail system may be located at a level below the container handling vehicle rail system on which multiple container handling vehicles operate. The delivery rail system (on which the delivery vehicles may operate) may be arranged in a grid pattern in the same (or similar) manner as the container handling vehicle rail system. The delivery rail system may extend downward (below the delivery ports) across the lower level of the storage grid, covering at least one (preferably all) of the at least one delivery port and the distance from the storage grid to the second location.

Thus, the second location may be located at any predetermined location along the distribution rail system.
To maximize storage space for storage containers within a warehouse grid, it may be advantageous to arrange the distribution rail system so that it extends as little as possible into the storage grid, which means that the warehouse grid can include multiple storage columns extending from an upper level to the base of the storage grid, thus allowing for the maximum possible storage capacity, since the entire storage column can be used for storage.

To maintain the maximum possible storage capacity, the portion of the delivery rail system that extends into the storage grid can be kept as small (to a small extent) as possible. Thus, the delivery rail system and delivery vehicles can occupy as little space as possible in the warehouse grid, which can be used for storing storage containers.

Each grid cell of the delivery rail system can have a size equal to or similar to that of a grid cell of the rail system for the container handling vehicle. In addition to expediting production and ensuring costs by enabling the use of already designed and tested components, the required alignment of the delivery vehicle below the upper rail system for the container handling vehicle becomes more achievable.

The typical width of each grid cell of the delivery rail system is in intervals of 30 cm to 150 cm, and the typical length is in intervals of 50 cm to 200 cm.
The width and length of each grid opening is typically 2 cm to 10 cm smaller than the width and length of the corresponding grid cell (FIG. 2C).

Because delivery vehicles may be operating directly below container handling vehicles on top of the storage grid, their dimensions may naturally correspond to the grid cell size of the storage grid above. Many of the same considerations apply as for container handling vehicles, such as the ability for vehicles to pass each other on adjacent grid cells. However, for delivery vehicles, a single grid space configuration also has other advantages, such as avoiding interference with upright members of the storage grid.

The automated storage system of the present invention is more effective than prior art systems by avoiding or at least reducing congestion of storage containers around the delivery columns of the storage grid. Therefore, the addition of a dedicated delivery rail system increases the overall capacity of the storage system because storage containers can be instantly and continuously moved away from the delivery column area. This means that container handling vehicles do not have to wait for an available delivery column to drop off the storage containers. Similarly, container handling vehicles continuously receive (pick up) storage containers from the delivery port for storage within the storage grid.

The delivery rail system may include a first set of parallel rails and a second set of parallel rails, the first set of parallel rails being arranged in a horizontal plane to guide movement of the delivery vehicle in a first direction X across the level of the delivery rail system, and the second set of parallel rails being arranged in a horizontal plane perpendicular to the first set of rails to guide movement of the delivery vehicle in a second direction Y perpendicular to the first direction X. In this manner, the delivery rail system defines a grid pattern over which the delivery vehicle can move laterally. The grid pattern thus includes a plurality of adjacent delivery vehicle grid cells, each grid cell including a grid opening, the grid opening defined by a pair of neighboring rails from the first set of rails and a pair of neighboring rails from the second set of rails.

The delivery rail system can be a single-track system. Alternatively, the rail system can be a double-track system, for example, where the two tracks in each rail are separated by a mid-way ledge. This double-track system allows a delivery vehicle to have a footprint equal to or less than the lateral extent of a grid cell, thereby allowing the delivery vehicle to travel along a row of grid cells even when another delivery vehicle is positioned in a neighboring grid cell in that row. In a double-track system, each delivery vehicle is configured to run on the inner rail of each double-track rail. Thus, the vehicle body does not extend beyond the midpoint of the parallel rails.

The delivery rail system may typically be located at ground floor level, thereby allowing easy access to the storage containers for human and/or robotic operators. However, the delivery rail system may be located at any level below the upper level of the storage grid. In a preferred configuration, the entire delivery rail system is located at a level below the pickup and/or drop-off ports of the storage grid.

The delivery system may include interfaces that allow connection to third party storage, production, and distribution systems.
The distribution system can be integrated with third party storage, production, and distribution systems such that storage containers can be transported between the distribution system and the third party storage, production, and distribution systems.

The distribution system of the present invention can be connected to third-party storage, production, and distribution systems, such as production facilities, storage grids, assembly facilities, receiving or shipping locations, etc. The connection can be by a connectable rail system or by a conveyor system including conveyors used to transport storage containers between the distribution system and the third-party storage, production, and distribution system. The delivery vehicle can include a weighing mechanism, such as a commercially available electronic weighing scale, to measure the weight of the storage containers. Such a weighing mechanism can provide information about the contents inside each storage container, such as total weight, number of units, internal weight distribution, and/or the location within the storage grid where the storage container should be located.

For example, if a storage container is particularly heavy, it may be recommended to place the storage container deeper in the storage grid. Alternatively or additionally, it may be recommended to send an alert signal to a human operator and/or robot operator who should handle the particular storage container.

The container carrier of the delivery vehicle can be a container support device for supporting a storage container from below.
The support device can be (or can include) a base plate, a conveyor, and/or any other structure capable of transporting storage containers from below.

To stabilize the storage container in the horizontal plane (P), the support device may include at least one raised edge located at or near the periphery of the base plate and/or conveyor, etc.

The container support device may be arranged to either support the storage container from below or to hold/suspend the storage container from at least one raised edge, or a combination thereof.

The container support device can be at least any one of a lid, a tray, a box, or a crate.
The support device can include a base plate with a raised edge to form a compartment having a compartment size adapted to receive the storage container. The compartment can be adapted to receive at least a lower section of the storage container (e.g., at least a base of the storage container).

Additionally, the compartment may be positioned to completely contain the storage container.
In a mixed storage container system, the size of the support device's compartments can be adapted to accommodate the size of the largest storage container in the storage grid, allowing the compartments to accommodate both small and large storage containers. The large containers can be supported from below by a platform or structure, while the small containers can be supported by a raised edge of the compartment. Additionally, the container carrier can include a conveyor.

The conveyor can include rolls with or without integrated motors mounted between supports (e.g., parallel railings) for each end of the rolls. The rolls allow storage containers to be shifted into or out of the container carrier. Additionally, the rolls provide support from below for the storage containers while they are positioned on the delivery vehicle.

Different types of conveyors may be used, such as conveyor belts, wheels, balls, rods, or any similar means adapted for easy movement of storage containers into or out of the container carrier.

The container carrier of the delivery vehicle may include a displacement device arranged to move the container carrier relative to the rolling device of the delivery vehicle. The displacement device may generally be capable of moving the container carrier in any direction (e.g., vertically) and thereby acting as a lifting device, and/or of moving the container carrier to any side by horizontal displacement and/or by tilting the container carrier about a pivot axis using a tilting device. The latter, among other things, facilitates handling or picking operations during handling by a human operator. The tilting movement is preferably performed around one of the main directions of movement of the delivery vehicle, for example around the X and/or Y direction.

Thus, the pivot axis can be parallel to the first set of rolling devices, or parallel to the second set of rolling devices, or both.

The above-described embodiments allow a storage container located on a container carrier to be tilted toward a user at a second location or any suitable location. In addition to improving the operator's working position while retrieving and/or inserting items into the storage container, the tilted position of the storage container allows a human operator to easily view the contents stored therein. The tilt angle range is from 2° to 60°, more preferably from 3° to 50°, even more preferably from 4° to 45°, even more preferably from 5° to 40°, even more preferably from 6° to 35°, even more preferably from 7° to 30°, even more preferably from 8° to 25°, even more preferably from 9° to 20°, and can be, for example, 15°, to one or both sides of the pivot axis relative to the horizontal plane. The ability to tilt the storage container, among other things, allows a human operator to more easily view and/or access items within the storage container.

Generally, the tilt angle should not exceed a maximum tilt angle, which would represent a significant risk of stored items/articles tipping out of the container in question. This maximum allowable tilt angle depends on the amount and size of the items/articles in the storage container. A storage container filled with items up to its upper edge will have a lower maximum tilt range than a storage container with items that only partially fill the vertical height of the container.

The displacement device may include a lifting arm connected to the container carrier, the lifting arm being operated by a tilt motor located within the vehicle body, and the tilting arm may be operated by a linear actuator. The displacement device's range of motion may be governed by a set maximum tilt range. For example, a tilting arm connected to a linear actuator may be configured to allow tilting up to 30°, up to 25°, up to 20°, or up to 15°. The tilt angle may be fixed or adjustable. In the latter case, any adjustment may be achieved by remote control and/or manual interaction by a human operator.

The motors providing the power required to drive the delivery vehicle in the X or Y direction can be one or more dedicated electric motors, which are, for example, at least partially (preferably completely) located within the rolling device.

The rolling device can be any device that ensures horizontal propulsion of the delivery vehicle, for example wheels and/or belts.
In a preferred embodiment, the delivery vehicle includes a wheel structure. The wheel structure may further include a first set of wheels and a second set of wheels, the first set of wheels being arranged on opposite sides of the vehicle body or vehicle base for moving the delivery vehicle along a first direction (X) on the delivery rail system, and the second set of wheels being arranged on opposite sides of the vehicle body or vehicle base for moving the delivery vehicle along a second direction (Y) on the delivery rail system, the second direction (Y) being perpendicular to the first direction (X).

The delivery vehicle may include a vehicle body and a wheel structure of eight wheels, with a first set of four wheels permitting lateral movement of the delivery vehicle in a first direction (X) and a second set of four wheels permitting lateral movement in a second direction (Y). One or both sets of wheels in the wheel structure may be lifted and lowered so that the first set of wheels and/or the second set of wheels may engage with a respective set of rails provided on the delivery rail system at any one time.

As mentioned above, a delivery vehicle can have a predetermined footprint, i.e., extent in the X and Y directions, that is generally equal to the horizontal extent of a grid cell of the delivery rail system, i.e., that is generally equal to the extent of a grid cell in the X and Y directions.

Alternatively, the delivery vehicle may have a footprint larger than the lateral extent of a grid cell of the delivery rail system.
In a second aspect, the present invention relates to an automated warehouse system.

The automated storage system may include an automated storage grid and a distribution system, where the distribution system may be arranged for transporting storage containers between the storage grid and a second location. The second location may be a location where a robotic operator and/or a human operator handles the storage containers, for example, by storing and/or retrieving items in the storage containers.

The grid may include a container handling vehicle rail system for guiding a plurality of container handling vehicles, the rail system including a first set of parallel rails and a second set of parallel rails, the first set of parallel rails being arranged in a horizontal plane and extending in a first direction, and the second set of parallel rails being arranged in the horizontal plane and extending in a second direction orthogonal to the first direction, the first and second sets of rails forming a grid pattern in the horizontal plane. The rails of the sets define a grid including a plurality of adjacent container handling vehicle grid cells, each container handling vehicle grid cell including a container handling vehicle grid opening defined by a pair of adjacent rails of the first set of rails and a pair of adjacent rails of the second set of rails. The delivery column is adapted for transporting storage containers arranged in the stack of storage containers below the container handling vehicle rail system between the container handling vehicles and a delivery port located at the lower end of the delivery column.

The delivery system may include a remotely operated delivery vehicle including a container carrier configured to support a storage container. The delivery vehicle may be adapted to transport the container carrier between a delivery port and a second location, the second location being for handling the storage container by at least one of a robotic operator and a human operator.

The delivery vehicle may include a rolling device connected to a vehicle body or vehicle base positioned below the container carrier.
As previously described, the distribution column can include a distribution port located at a lowermost end of the distribution column. In operation, storage containers can be transported through the storage column to the distribution port, where they are placed on or into a delivery vehicle. The delivery vehicle can then deliver the storage container to the distribution port for transport through the distribution column and to be received by a container handling vehicle.

The delivery system of the automated warehouse system may further include a delivery rail system below the delivery port. The delivery rail system may further be positioned such that a delivery vehicle can operate on the rail system when traveling between the delivery port and a predetermined second location.

Each of the at least one delivery rail system may include a first set of parallel rails and a second set of parallel rails, the first set of parallel rails being disposed in a horizontal plane (P1) and extending in a first direction (X), and the second set of parallel rails being disposed in the horizontal plane (P1) and extending in a second direction (Y) orthogonal to the first direction (X). The first and second sets of rails define a grid in the horizontal plane (P1) that includes a plurality of adjacent delivery vehicle grid cells, each delivery vehicle grid cell including a delivery vehicle grid opening, the delivery vehicle grid opening being defined by a pair of neighboring rails of the first set of rails and a pair of neighboring rails of the second set of rails.

Each of the first and second sets of rails of the delivery rail system may be a double-track rail including two parallel tracks separated by a projection running between them.

In addition, each of the first and second sets of rails of the container handling vehicle rail system may be a double-track rail including two parallel tracks separated by a projection running between them.

A remotely operated delivery vehicle may have a delivery vehicle footprint with a horizontal extent equal to or less than the horizontal extent of a delivery vehicle grid cell.
Moreover, at least one (preferably each) of the plurality of delivery vehicle grid cells of the delivery rail system may be located directly below a container handling vehicle grid cell of the container handling vehicle rail system. The delivery rail system may extend into the framework structure of the storage grid. Thus, the second location is located inside the framework structure of the storage grid.

The delivery rail system may extend outside the framework structure of the storage grid, preferably to a second location. When the second locations are located outside the storage grid, they do not occupy the storage capacity of the grid.

The delivery rail system may include a first rail system positioned within the framework structure of the storage grid and a second rail system positioned outside the framework structure of the storage grid, the first and second rail systems being connected such that delivery vehicles can operate between the rail systems.

The second location may be connected to a second rail system.
The second location can be located anywhere on the delivery rail system, at or through which storage containers can be deposited and/or retrieved. Because the second location can be any predetermined location on the delivery rail system, the second location can be moved, a new second location can be established/opened, or an existing second location can be removed/closed.

In a third aspect, the present invention relates to a method for transporting storage containers between an automated warehouse grid and a second location, the second location being for handling the storage containers by at least one of a robotic operator and a human operator.

The automated warehouse grid may include a container handling vehicle rail system including a first set of parallel rails and a second set of parallel rails, the first set of parallel rails being arranged in a horizontal plane and extending in a first direction and the second set of parallel rails being arranged in the horizontal plane and extending in a second direction orthogonal to the first direction, the first and second sets of rails defining a grid in the horizontal plane including a plurality of adjacent container handling vehicle grid cells, each grid cell including a container handling vehicle grid opening, the container handling vehicle grid opening being defined by a pair of neighboring rails of the first set of rails and a pair of neighboring rails of the second set of rails; and a plurality of stacks of storage containers arranged in storage columns positioned below the container handling vehicle rail system, each storage column being positioned vertically below a container handling vehicle grid opening.

The system may further include a delivery column configured to receive the storage container from the container handling vehicle.
The method is:
- lowering the storage container through at least one delivery column to a delivery port;
positioning a delivery vehicle below the delivery port to receive a storage container on a container carrier;
delivering the storage container to the second location by operating a rolling device of the remotely operated delivery vehicle on the delivery rail system.

The method may preferably further comprise tilting the container carrier at the second location within a tilting angle range between 2° and 60° relative to the horizontal plane (P, P1), or within any of the tilting angle ranges mentioned above.

The second location may include a picking station and the tilting of the storage container may be to assist in the picking operation.
The method can include operating the remotely operated delivery vehicle back to the delivery port by operating a rolling device of the remotely operated delivery vehicle on the delivery rail system, and lifting the storage container through the delivery column for storage of the storage container within the automated warehouse grid.

In a fourth aspect, the present invention relates to an automated warehouse system including an automated warehouse grid and a remotely operated carrier vehicle.
The automated warehouse grid includes a rail system for guiding remotely operated container carrying vehicles operating on the rail system.

The rail system may include a first set of parallel rails and a second set of parallel rails, the first set of parallel rails being disposed in a horizontal plane (P) and extending in a first direction (X), and the second set of parallel rails being disposed in the horizontal plane (P) and extending in a second direction (Y) perpendicular to the first direction (X).

The first and second sets of rails form a grid pattern in a horizontal plane (P) including a plurality of adjacent grid cells, each grid cell including a grid opening defined by a pair of neighboring rails in the first set of rails and a pair of neighboring rails in the second set of rails. Each rail may include a pair of tracks, each track configured to guide a wheel in a first direction or a second direction (X, Y).

The container transport vehicle may include rolling means, the rolling means including a first set of wheels and a second set of wheels, the first set of wheels being symmetrically arranged about a vertical mid-plane of the vehicle oriented in a first direction (X) for moving the container transport vehicle along the first direction (X) on the rail system, and the second set of wheels being symmetrically arranged about a vertical mid-plane of the container transport vehicle oriented in a second direction (Y) for moving the container transport vehicle along the rail system along the second direction (Y), at least one of the first and second sets of wheels being vertically displaceable relative to the rail system by a displacement motor.

The container transport vehicle further includes a container carrier adapted to support the storage container from below. The container carrier may be tiltable.
The automated warehouse system according to the fourth aspect may include any of the features described with respect to the first, second and/or third aspects.

In particular, the rail system of the fourth aspect may include any of the features describing the automated warehouse grids described with respect to the second and/or third aspects.
Additionally, the container transport vehicle of the fourth aspect may include any of the features describing the remotely operated delivery vehicle described with respect to the first, second, and/or third aspects.

With respect to the fourth aspect of the present invention, one or more of the container transport vehicles may cooperate with one or more container handling vehicles that deliver and retrieve storage containers in the stack below. For example, a container transport vehicle may have the purpose of acting as an additional storage location for storage containers (such as storage containers that need to be stored on the grid for short periods of time). At other times, the container transport vehicle may be delivering or retrieving storage containers between two locations.

The following drawings illustrate exemplary embodiments of the present invention and are included to facilitate understanding of the present invention.

FIG. 1 is a perspective view of a prior art automated storage system showing the complete system. FIG. 1 is a perspective view of a prior art automated warehouse system, showing an example of a prior art container handling vehicle capable of operating in the system. FIG. 1 is a perspective view of a prior art automated storage system showing the complete system. FIG. 1 is a perspective view of a prior art automated warehouse system, showing an example of a prior art container handling vehicle capable of operating in the system. FIG. 1 is a top view of a container handling vehicle rail system showing a single track system. FIG. 1 is a top view of a container handling vehicle rail system showing a double track system 2B. FIG. 1 is a top view of a container handling vehicle rail system showing the width and length shown in a double track system of container handling vehicle grid cells. FIG. 1 is a side view of a remotely operated delivery vehicle in accordance with an embodiment of the present invention. FIG. 1 is a side view of a remotely operated delivery vehicle in accordance with an embodiment of the present invention. FIG. 1 is a side view of a remotely operated delivery vehicle in accordance with an embodiment of the present invention. FIG. 3D is a perspective view of the remotely operated delivery vehicle of FIGS. 3A-3C. FIG. 3D is a perspective view of the remotely operated delivery vehicle of FIGS. 3A-3C. FIG. 3D is a perspective view of the remotely operated delivery vehicle of FIGS. 3A-3C from underneath. FIG. 3D is a perspective view of the remotely operated delivery vehicle of FIGS. 3A-3C from above. FIG. 3D is a cross-sectional view of the remotely operated delivery vehicle of FIGS. 3A-3C. FIG. 3D is a perspective view of the remotely operated delivery vehicle of FIGS. 3A-3C disclosing the operation of the wheels. FIG. 10 is a perspective view of another embodiment of a remotely operated delivery vehicle having a container carrier with compartments for holding storage containers. FIG. 10 is a perspective view of another embodiment of a remotely operated delivery vehicle having a container carrier with compartments for holding storage containers. FIG. 10 is a perspective view of another embodiment of a remotely operated delivery vehicle having a container carrier with compartments for holding storage containers. FIG. 10 is a perspective view of another embodiment of a remotely operated delivery vehicle having a conveyorized container carrier. FIG. 10 is a perspective view of another embodiment of a remotely operated delivery vehicle having a conveyorized container carrier. FIG. 1 is a perspective view of an exemplary embodiment of an automated warehouse grid and distribution system in accordance with the present invention. FIG. 1 is a perspective view of an exemplary embodiment of an automated warehouse grid and distribution system in accordance with the present invention. FIG. 1 is a perspective view of another embodiment of an automated warehouse grid and distribution system according to the present invention. FIG. 1 is a perspective view of another embodiment of an automated warehouse grid and distribution system according to the present invention. FIG. 10 is a perspective view of another embodiment of an automated warehouse grid with delivery columns and delivery ports. FIG. 1 is a side view of another automated embodiment warehouse grid and distribution system according to the present invention. FIG. 13 is a top view of a double track delivery rail system for the automated warehouse system according to FIGS. 9 to 12.

In the following, embodiments of the present invention will be discussed in more detail with reference to the accompanying drawings. However, it should be understood that the drawings are not intended to limit the present invention to the subject matter shown therein. Moreover, even if some of the features are described in relation to the system only, it will be apparent that they are equally valid in relation to the delivery vehicle and the related method, and vice versa. Thus, any feature described in relation to the delivery vehicle only and/or the related method is also valid in relation to the system.

Referring to Figures 1A-1D, the storage grids 104 of each storage structure 1 form a framework 100 of a total of 143 grid columns 112, with the width and length of the framework corresponding to the width and length of 13 and 11 grid columns 112, respectively. The upper layer of the framework 100 is a rail system 108, on which multiple container handling vehicles 200, 300 operate.

The framework 100 of the storage system 1 is constructed in accordance with the aforementioned prior art framework 100 described above, i.e., constructed in accordance with a plurality of upright members 102 and a plurality of horizontal members 103 supported by the upright members 102, and further constructed in accordance with the fact that the horizontal members 103 include a container handling vehicle rail system 108 of parallel rails 110, 111 in the X and Y directions, respectively, disposed across the top of the storage columns 105. The horizontal area of a single grid cell 122, i.e., the area along the X and Y directions, may be defined by the distance between adjacent rails 110 and 111, respectively (see also FIG. 2). In FIGS. 1A and 1C, such a grid cell 122 is marked above the rail system 108 by a bold line.

The container handling vehicle rail system 108 allows the container handling vehicles 200, 300 to move horizontally between different grid locations, each of which is associated with a grid cell 122.

1A and 1C, the storage grid 104 is shown with a height of eight cells. However, it is understood that the storage grid 104 can, in principle, be of any size. In particular, it is understood that the storage grid 104 can be significantly wider and/or longer than that disclosed in FIGS. 1A and 1C. For example, the grid 104 can have a horizontal extent of more than 700x700 grid cells 122. The grid 104 can also be significantly deeper than that disclosed in FIGS. 1A and 1C. For example, the storage grid 104 can be greater than 12 grid cells deep.

The storage container vehicles 200, 300 may be of any type known in the art, for example, any one of the automated container handling vehicles disclosed in WO2014/090684A1, NO317366, or WO2015/193278A1.

The rail system 108 can be a single track system, as shown in FIG. 2A. Alternatively, the rail system 108 can be a double track system, as shown in FIG. 2B. Details of single track and double track systems are disclosed herein under the Background and Prior Art sections.

3A-3C illustrate an embodiment of a remotely operated delivery vehicle 30 (hereinafter referred to as delivery vehicle 30) in accordance with the present invention.
The delivery vehicle 30 is configured for transport of one or more storage containers 106 (not shown) between an automated storage grid 104 (not shown) configured to store a plurality of stacks 107 of the storage containers 106 (hereafter referred to as the storage grid 104) and a second location for handling of the storage containers (106) by at least one of a robotic operator and a human operator (not shown). The delivery vehicle 30 may be configured for transport of only one storage container 106 or may be configured for transport of two or more storage containers simultaneously.

The delivery vehicle 30 includes a vehicle body 31, a rolling device 32 connected to the vehicle body 31, a rolling device motor for driving the rolling device 32 in a horizontal plane (P1), and a power source 43 connected to the rolling device motor. The power source 43 should provide sufficient power to the rolling device motor to propel the rolling device 32 along a set route from the storage grid 104 to, for example, a second location.

The delivery vehicle 30 may further include a container carrier 35 mounted above the vehicle body 31. The container carrier 35 should be configured to receive the storage container 106 on or within the container carrier 35, and the storage container 106 is prevented from moving horizontally relative to the container carrier.

The container carrier 35 may include a container support device that supports the storage container 106 from below. The container support device may be in any form that ensures stable support, such as in the form of a cup, cradle, seat, frame, holder, or platform.

In Figures 3A-3C, the container carrier 35 is disclosed in the form of a storage container-receiving compartment having a bottom/base and sidewalls. The compartment volume, in this exemplary configuration, is capable of receiving and containing the entire horizontal extent of the storage container and at least a portion of the vertical extent of the storage container. Figures 3-6 show an example of a container carrier 35 containing the entire storage container 106, while Figures 7A-7C show an alternative container carrier 35 containing a portion of the storage container 106.

The particular configuration of the container carrier 35 disclosed in Figures 3-6 allows the delivery vehicle 30 to transport storage containers 106 having different heights.
It should be noted that the size of the compartments within the container carrier 35 can be easily adapted to receive and support multiple storage containers 106 in one operation.

Figures 3B and 3C show a particular configuration of the delivery vehicle 30, in which the container carrier 35 can be set in a tilted position relative to the vehicle body 31 and the horizontal plane (P1). The container carrier 35 can be tilted by a dedicated displacement device 41. The tilting can be performed around a pivot axis oriented in the main direction of movement of the delivery vehicle 30. If the delivery vehicle 30 moves on vertical rails (see below), these main directions will be in either the X or Y direction.

Tilting of the displacement device 41 can be achieved, for example, by a lifting arm 45 connected to the vehicle body 31 and the container carrier 35. Furthermore, the lifting arm 45 can be driven by a dedicated tilt motor (not shown) or a rolling device motor, or both.

4A-4B show additional perspective views of the delivery vehicle 30. The rolling device 32, in this exemplary configuration:
a first set of wheels 32a arranged on both sides of a vertical central plane passing through the vehicle body 31 in order to move the delivery vehicle 30 along a first direction (for example along the X direction) on the delivery rail system;
a second set of wheels 32b arranged on both sides of a vertical central plane passing through the vehicle body 31, for moving the delivery vehicle 30 along a second direction (e.g., along a Y direction perpendicular to the first direction X) on the delivery rail system.

An example of a delivery rail system will be further described in Figures 9-12.
5A and 5B show delivery vehicle 30 from below and above, respectively. As can be clearly seen in FIG. 5A, vehicle body 31 of delivery vehicle 30 includes internal component-receiving recesses or compartments for containing components such as, for example, one or more dedicated tilt motors 41, one or more rail-shift motors 42, one or more power storage sources such as batteries 43, and one or more control cards such as a CPU and/or Power PCB 44. Thus, the above-mentioned components are positioned within vehicle body 31 below container carrier 35.

As best shown in FIG. 5B, the storage container receiving compartment of the container carrier 35, in this particular configuration, has a rectangular bottom or base plate with vertical side walls. The vertical side walls can be of any height, so long as they ensure that the storage containers 106 are restricted from moving along the container carrier's base plate.

For example, the size of the compartment 35 corresponds to the size of the storage container 106 so that it can completely contain the storage container 106 .
The delivery vehicle can have a footprint (i.e., extent in the X and Y directions) that is generally equal to the horizontal extent of a grid cell of the delivery rail system (i.e., extent of the grid cell in the X and Y directions). Thus, the size of the base plate of compartment 35 in the X and Y directions can be within these given perimeters.

In cases where the container carrier 35 is configured to support multiple storage containers 106, the size of the vertical wall may, in one example, be the height of each storage container 106, and the size of the base plate may be the aggregate cross-sectional area of all storage containers 106 measured relative to the outer lateral edges of the storage containers 106.

Figure 5B further illustrates that the container carrier 35 can include dedicated holding devices 46, 47, 49 for one or more storage containers 106, allowing storage containers 106 of different vertical heights to be stored within the same delivery vehicle 30. In the exemplary configuration shown in Figure 5B, the holding device includes a support element 46 having an upper surface 49 and connected to an actuator lever 47. The support element 46 is connected to an inner wall of the container carrier 35, for example, in the upper half of the container carrier 35.

The retention device may be arranged in the following exemplary manner.
The storage container holding device comprises a support element 46 having an upper surface 49 at one end and connected at an opposite end to an actuator lever 47. The support element is pivotally connected to the inner upper part of the side wall of the compartment 35. The actuator lever 47 is arranged at an inclination angle such that it protrudes into the compartment 35 such that during introduction of a storage container 106 into the compartment 35, the bottom edge of the storage container 106 pushes the actuator lever 47 from the protruding position (in which the actuator lever 47 is in contact with the bottom edge of the storage container) to a substantially vertical position.

Because the actuator lever 47 is pivotally connected to the support element 46, movement of the actuator lever 47 provides a corresponding movement of an upper surface 49 provided at the opposite end of the support element 46. Thus, the compartment 35
During introduction of storage container 106 into compartment 35, top surface 49 moves from a first position where top surface 49 is not in contact with the top edge of the storage container, and in the second position where top surface 49 is in contact with the top edge of the storage container when storage container 106 is fully seated within compartment 35. In the second position, the top edge of the storage container (not shown) is supported by top surface 49.

The actuator levers 47 may be pretensioned by springs (not shown) so that the actuator levers 47 return to their inactivated (extended) position when the storage container 106 is lifted away from (or out of) the compartment 35.

By supporting the storage container 106 via its outer upper edge (not shown), the storage container 106 is always held at a predetermined level relative to the base plate of the compartment 35.

The support element 46, the upper surface 49 and the actuator lever 47 may be made in one piece.
FIG. 6A shows a side perspective view of the delivery vehicle 30 in which the container carrier 35 is tilted about an axis of rotation oriented in one of the primary directions of movement of the storage container 106 (i.e., the first direction or the second direction as described above).

The tilting of the displacement device 41 can be obtained, for example, by a lifting arm 45 .
The container carrier 35 can be tilted towards one of its longitudinal sides so that the storage containers 106 can be easily accessed by a human operator responsible for picking items from within the container carrier 35.

The displacement device 41 is shown in FIG. 6A as having an L-shaped lifting arm 45 connected on one side to the vehicle body 31 and on the other side to a structure fixed to the container carrier 35. Alternatively, the latter end of the arm 45 may be directly connected to the container carrier 35.

The tilt motor 41 is seen to be located entirely inside the vehicle body 31 and is directly or indirectly connected to the lifting arm 45 to move the lifting arm 45 between a lower position in which the container carrier 35 is not tilted relative to the horizontal plane (P) and an upper position in which the container carrier 35 is tilted relative to the horizontal plane (P). It should be noted that the horizontal plane (P) may be defined as the plane established by the particular configuration of the wheels 32a, 32b of the rolling device 32.

Figure 6B shows a delivery vehicle 30 as described above, with a vehicle body 31 and a rolling device 32 of eight wheels 32a, 32b. With respect to the delivery vehicles shown in Figures 3-5, a first set of four wheels 32a allows for lateral or horizontal movement of the delivery vehicle 30 in a first direction, and a second set of four wheels 32b allows for lateral or horizontal movement in a second direction, which may be perpendicular to the first direction.

When used on a delivery rail system 50 (see below), one or both sets of wheels 32a, 32b of the rolling device 32 should be lifted and lowered so that the first set of wheels 32a and/or the second set of wheels 32b can be engaged with the respective sets of rails provided on the delivery rail system 50 at any one time.

Figures 7A-7C show another exemplary configuration of a remotely operated delivery vehicle 30 according to the present invention. Similar to the container carrier 35 described above, the container carrier 35 in this configuration is a container support device for supporting a storage container 106 from below.

The container support device thus includes a base plate provided with sidewalls along its periphery or perimeter, thereby defining a compartment. The horizontal extent of the compartment is adapted to be large enough to receive one or more storage containers 106 and small enough to substantially prevent movement of the one or more storage containers 106 when inserted. However, in contrast to the exemplary configuration of the delivery vehicle 30 shown in Figures 3-6, the one or more sidewalls of the container support device have a vertical height that is smaller than the vertical height of the respective storage containers 106. In fact, to achieve the purpose of the sidewalls of the container carrier 35 (to substantially prevent horizontal movement when inserted), it is sufficient to provide only a small vertical protrusion upward from the base plate, e.g., less than 5% of the height of the sidewalls of the storage containers 106.

Figures 8A-8B show yet another exemplary configuration of a remotely operated delivery vehicle 30. In this configuration, a container carrier 35 includes a base plate, a conveyor 36 disposed on the base plate, and two parallel sidewalls projecting upward from the base plate. The rolling device 32 and vehicle body 31 are identical to or similar to the rolling device 32 and vehicle body 31 described above in connection with Figures 3-7.

The conveyor 36 may be configured, inter alia, by a plurality of parallel-oriented rolls 36 having a common longitudinal direction perpendicular to the two side walls. In this way, the rolls 36 allow one or more storage containers 106 to be shifted into or out of the container carrier 35 while being guided by the side walls. The conveyor may be connected to a conveyor motor that enables rotation of one or more of the rolls.

Alternatively, the sidewalls may be omitted, allowing the storage container 106 to have a horizontal offset relative to a vertical center plane oriented perpendicular to the roll length. Thus, the storage container 106 may be positioned such that it extends beyond the ends of the roll in the roll length direction.

In yet another alternative configuration, the conveyor can include multiple rolling balls in or on the base plate of the container carrier 35, allowing one or more storage containers 106 to roll on the balls. With this configuration, and the absence of side walls, the storage containers 106 can be moved in any direction above the base plate.

Perspective views of an automated warehouse system are shown in Figures 9A and 9B. The system includes a storage grid 104 and a delivery system 140 including the delivery vehicle 30 described above.

The storage grid 104 is equal to or similar to the prior art storage grid 104 described above, i.e., a storage grid 104 including a rail system 108, a plurality of stacks 107 of storage containers 106, a plurality of container handling vehicles 300 for lifting and moving the storage containers 106 stacked in the stacks 107, and delivery columns 119, 120 configured to receive the storage containers 106 from the container handling vehicles 300.

The rail system 108 includes a first set of parallel rails 110 and a second set of parallel rails 111, where the first set of parallel rails 110 are disposed in a horizontal plane (P) and extend in a first direction (X), and the second set of parallel rails 111 are disposed in the horizontal plane (P) and extend in a second direction (Y) perpendicular to the first direction (X). The first and second sets of rails 110, 111 form a grid pattern in the horizontal plane (P) that includes a plurality of adjacent grid cells 122. Each grid cell 122 represents a grid opening, which is defined by a pair of neighboring rails of the first set of rails 110 and a pair of neighboring rails of the second set of rails 111.

Multiple stacks 107 are arranged in storage columns 105 positioned below the rail system 108, with each storage column 105 positioned vertically below a grid cell 122.

Each container handling vehicle 200 , 300 is configured to travel on a rail system 108 above the storage columns 105 .
Additionally, distribution system 140 includes one or more of the delivery vehicles 30 as described above, i.e., delivery vehicles 30 configured to receive and support one or more storage containers 106 for transport between one or more distribution columns 119, 120 and one or more predetermined locations outside of storage grid 104. The predetermined location can be, for example, a second location, a conveyor line, or a transport vehicle, such as a truck.

The delivery system 140 may further include a delivery rail system 50, which is located below the delivery ports 150 of one or more delivery columns 119, 120.

As shown in Figures 9A-9B, the delivery rail system 50 may be constructed in the same manner or in a similar fashion as the rail system 108 for the container handling vehicles 200, 300.

Thus, the delivery rail system 50 may include a first set of parallel rails 51 and a second set of parallel rails 52, the first set of parallel rails 51 being arranged in a horizontal plane (P1) and extending in a first direction (X), and the second set of parallel rails 52 being arranged in the horizontal plane (P1) and extending in a second direction (Y) perpendicular to the first direction (X).

The delivery rail system 50 may also be a double-rail system, as shown in FIG. 2B, thus allowing a delivery vehicle 30 having a footprint generally corresponding to the lateral area defined by the delivery grid column to travel along a row of grid columns (even when another delivery vehicle 30 is positioned above a neighboring grid column in that row).

Both the single rail system and the double rail system, or a combination including single and double rail configurations in a single rail system, form a grid pattern or grid cells in a horizontal plane P1 including a plurality of rectangular and uniform grid locations, where each grid cell includes a grid opening bounded by a pair of rails of the first set of rails and a pair of rails of the second set of rails.

Pairs of rails in the X direction define parallel rows of distribution grid cells running in the X direction, and pairs of rails in the Y direction define parallel rows of distribution grid cells running in the Y direction.
Thus, each distribution grid cell has a width _Wc that is typically in the interval of 30 cm to 150 cm, and a length _Lc that is typically in the interval of 50 cm to 200 cm. Each grid opening 115 has a width _Wo and a length _Lo that are typically 2 cm to 10 cm smaller than the width _Wc and length _Lc of the distribution grid cell.

The delivery rail system 50 may be fully or partially integrated into the storage grid 104. However, it is considered advantageous to ensure effective operation for the delivery rail system 50 to have a horizontal extent that covers the delivery port 150 below at least one of the delivery columns 119, 120.

Figures 9A and 9B show a delivery rail system 50 extending from a location inside the storage grid 104 to a location outside the storage grid 104. One or more second locations, i.e., structures for picking and placing items in storage containers 106, may be located anywhere around the portion of the delivery rail system 50 that is positioned outside the storage grid 104. Alternatively or in addition, conveyors may be located at or near the same perimeter of the delivery rail system 50.

Figures 10A-10B show the automated warehouse system of the present invention on a larger scale, in which multiple delivery columns 119, 120 with their respective delivery ports are positioned at different locations within the storage grid 104.

The delivery rail system 50 may be arranged so that it connects to multiple delivery columns 119 , 120 provided at different locations within the storage grid 104 .
10 , the delivery rail system 50 may be divided into three interconnected zones, where a first zone is located within a first portion of the storage grid 104, a second zone is located within a second portion of the storage grid 104, and a middle zone is located outside the storage grid 104 and allows the delivery vehicles 30 to travel from the first zone to the second zone. The first and second zones are separated by a plurality of storage columns 105.

FIG. 11A shows multiple delivery columns 119, 120 of the storage grid 104. Each delivery column 119, 120 is arranged with a delivery port 150, which is located at the lowest level/end of the delivery column 119, 120.

A side view of the automated storage system 1 is shown in FIG. 11B. The system 1 includes an automated storage grid 104 and a distribution system 140. The distribution system 140 includes a delivery vehicle 30 adapted to travel on a distribution rail system 50 positioned below delivery ports 150 of delivery columns 119, 120 of the storage grid 104 (FIG. 11A). Container handling vehicles 200, 300 operate on the rail system 108 to pick up and drop off storage containers through the distribution columns 119, 120. The delivery vehicle 30 is operated so that it can accept storage containers 106 or deliver storage containers 106 to the delivery ports 150. The container storage column 105 is shown in FIGS. 9-11 without containing a storage container 106. During operation, the storage column 105 is filled or nearly filled with storage containers 106 stacked one on top of the other.

The distribution system can benefit from many of the considerations provided with respect to the rail system 108 of the storage grid 104 and the container handling vehicles 200, 300. As shown in FIGS. 10 and 11 , the upright members 102 of the storage grid 104 are shortened and suspended on a mezzanine level 151, which itself has upright posts 152 that can be extended from the distribution columns 119, 120 to horizontal positions typically positioned adjacent to the vertical sidewalls of the rails 110, 111 that frame the corresponding grid cells 122. Consequently, employing the distribution system 140 may result in a slight loss of storage space within the storage grid 104. However, the benefit is improved distribution efficiency of the storage containers 106 within the automated warehouse system 1. This is because congestion of storage containers 106 in the delivery columns 119, 120 is avoided or at least reduced. The number of delivery columns 119, 120 and the size (extent) of the mezzanine level 151 in the X and Y directions can be customized according to the size of the storage system and the desired efficiency of the system.

Figure 12 shows a delivery rail system 50 such as a double track rail system (i.e., identical to the double track rail system of the container handling rail system 108 disclosed in Figure 2C). With respect to the container handling rail system 108, each delivery vehicle grid cell 53 has a width _Wc that is typically in intervals of 30 cm to 150 cm, and a length _Lc that is typically in intervals of 50 cm to 200 cm. Each delivery vehicle grid opening 54 has a width _Wo and a length _Lo that are typically 2 cm to 10 cm smaller than the width _Wc and length _Lc of the grid cell 53.

In the X and Y directions, neighboring delivery vehicle grid cells 53 are positioned in contact with each other so that there is no space between them.
In the preceding description, various aspects of the delivery vehicle and automated warehouse system according to the present invention have been described with reference to illustrative embodiments. For purposes of explanation, specific numbers, systems, and configurations have been set forth to provide a thorough understanding of the system and its operation. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiments, as well as other embodiments of the system that are apparent to those skilled in the art of the disclosed subject matter, are deemed to be within the scope of the present invention.

30 Delivery vehicle 31 Vehicle body 32 Rolling device 32a First set of wheels 32b Second set of wheels 35 Container carrier 36 Rolls 37, 37' Delivery vehicle footprint 41 Displacement device 42 Tilt motor 43 Power supply 44 Controller 45 Lifting arm 46 Support element 47 Actuator lever 50 Delivery rail system 51 First set of parallel rails 51a First neighboring rail of the first set 51b Second neighboring rail of the first set 52 Second set of parallel rails 52a First neighboring rail of the second set 52b Second neighboring rail of the second set 53 Delivery vehicle grid cell 54 Delivery vehicle grid opening P1 Horizontal plane of delivery rail system 100 Framework structure 102 Upright members of the framework structure 103 Horizontal members of the framework structure 104 Storage grid/3-dimensional grid 105 Storage column 106 Storage container 107 Stack 108 Rail system/container handling vehicle rail system 110 First set of parallel rails in a first direction (X) 110a First neighboring rail of the first set 110b First neighboring rail of the first set 111 Second set of parallel rails in a second direction (Y) 111a First neighboring rail of the second set 111b Second neighboring rail of the second set 115 Grid opening/container handling vehicle grid opening 119 Delivery column 120 Delivery column 122 Grid cell/container handling vehicle grid cell 140 Delivery system 150 Delivery port 151 Mezzanine level 152 Upright post 200 First container handling vehicle 201 Wheel structure 202, 202′ Container handling vehicle footprint 300 Second container handling vehicle 301 Wheel structure X First direction Y Second direction P Horizontal plane of the rail system Wo Width of container handling vehicle grid opening Wc Width of container handling vehicle grid cell Lo Length of container handling vehicle grid opening Lc Length of container handling vehicle grid cell Wod Width of delivery vehicle grid opening Wcd Width of delivery vehicle grid cell Lod Length of delivery vehicle grid opening Lcd Length of delivery vehicle grid cell

Claims (20)

A remotely operated delivery vehicle (30) for transporting storage containers (106) between an automated storage and retrieval grid (104) and a second location, comprising:
the automated storage and retrieval grid (104) is configured to store a plurality of stacks (107) of storage containers (106);
The remotely controlled delivery vehicle (30)
a rolling device (32) configured to move the remotely operated delivery vehicle (30) in a horizontal plane (P1);
a rolling device motor for driving the rolling device (32);
a power source (43) configured to provide a propulsive force to the rolling device motor;
a container carrier (35) that supports the storage container (106) from below;
the container carrier (35) comprises a holding device (46, 47, 49) for one or more storage containers (106);
The holding device (46, 47, 49) comprises a support element (46) having an upper surface (49);
The support element (46) is connected to an actuator lever (47),
the support element (46) is connected to an inner wall of the container carrier (35);
the upper surface (49) is configured to suspend the one or more storage containers;
A remotely controlled delivery vehicle (30). The upper surface (49) of the support element (46) is located at one end of the support element (46);
The support element (46) is connected to the actuator lever (47) at the other end of the support element (46).
The remotely operated delivery vehicle (30) of claim 1. The support element (46) is pivotally connected to the upper end of the inner side wall of the container carrier (35).
A remotely controlled delivery vehicle (30) according to claim 1 or 2. the actuator lever (47) is pretensioned by a spring so that the actuator lever (47) returns to its inactive position when the storage container (106) is lowered or released from the container carrier (35);
A remotely controlled delivery vehicle (30) according to any one of claims 1 to 3. the support element (46), the upper surface (49) and the actuator lever (47) are made in one piece;
A remotely controlled delivery vehicle (30) according to any one of claims 1 to 4. The container carrier (35) includes a base plate having a side wall portion along its periphery;
The sidewalls of the container carrier (35) have a vertical height that is lower than that of the storage container (106).
A remotely controlled delivery vehicle (30) according to any one of claims 1 to 5. The vertical height of the sidewalls of the container carrier (35) is less than 5 percent of the vertical height of the sidewalls of the storage container (106).
7. The remotely operated delivery vehicle (30) of claim 6. The container carrier (35)
A base plate and
a conveyor (36) disposed on the base plate;
A remotely controlled delivery vehicle (30) according to any one of claims 1 to 5. The conveyor (36) includes a plurality of rolls (36) oriented in parallel with a common longitudinal direction.
9. The remotely operated delivery vehicle (30) of claim 8. The container carrier (35) further includes two parallel sidewall portions projecting upward from the base plate;
the common longitudinal direction of the rolls (36) is perpendicular to the two parallel side walls;
10. The remotely operated delivery vehicle (30) of claim 9. The conveyor (36) includes a plurality of rolling balls located in or on the base plate of the container carrier (35).
9. The remotely operated delivery vehicle (30) of claim 8. 1. An automated storage and retrieval system comprising: an automated storage and retrieval grid (104) for storage of storage containers; and a delivery system (140) for transporting the storage containers between the automated storage and retrieval grid (104) and a second location, wherein the automated storage and retrieval grid (104) comprises:
A plurality of storage columns (105) arranged in a row, each containing a storage container (1
a plurality of storage columns (105) in which the storage columns (105) are stacked in a row of the storage columns (105);
delivery columns (119, 120) disposed within the automated storage and retrieval grid for transporting the storage containers (106) between the automated storage and retrieval grid and the delivery system;
The delivery system comprises:
12. The remotely operated delivery vehicle (30) of any one of claims 1 to 11, adapted to receive the storage container (106) from the delivery column (119, 120) for transport of the storage container (106) between the automated storage and retrieval grid (104) and the second location.
Including,
Automated storage and retrieval system. The automated storage and retrieval grid (104)
A container handling vehicle rail system (108) for guiding a plurality of container handling vehicles (200, 300), comprising:
the container handling vehicle rail system (108) includes a first set of parallel rails (110) and a second set of parallel rails (111);
The first set of parallel rails (110) are disposed in a horizontal plane (P) and extend in a first direction (X);
the second set of parallel rails (111) are arranged in the horizontal plane (P) and extend in a second direction (Y) perpendicular to the first direction (X);
the first and second sets of rails (110, 111) form a grid pattern in the horizontal plane (P) comprising a plurality of adjacent container handling vehicle grid cells (122);
each of the plurality of container handling vehicles is adapted to retrieve the storage container (106) from the storage column (105) and to deliver the storage container (106) to the delivery column (119, 120);
Container handling vehicle rail system (108)
Including,
The automated storage and retrieval system of claim 12. The delivery system (140) includes a delivery rail system (50);
The delivery vehicle (30) operates on the delivery rail system (50);
The delivery system (140) is located below the delivery ports (150) of the delivery columns (119, 120).
14. The automated storage and retrieval system of claim 13. The delivery rail system (50) includes a first set of parallel rails (51) and a second set of parallel rails (52);
the first set of parallel rails (51) are arranged in a horizontal plane (P1) and extend in a first direction (X);
the second set of parallel rails (52) are disposed in the horizontal plane (P1) and extend in a second direction (Y) perpendicular to the first direction (X);
the first and second sets of rails (51, 52) form a grid pattern in the horizontal plane (P1) comprising a plurality of adjacent delivery vehicle grid cells (53);
Each of the delivery vehicle grid cells (53) includes a delivery vehicle grid opening (54);
the delivery vehicle grid opening (54) is defined by a pair of adjacent rails (51 a, 51 b) of the first set of rails (51) and a pair of adjacent rails (52 a, 52 b) of the second set of rails (52);
15. The automated storage and retrieval system of claim 14. the remotely operated delivery vehicle (30) having a delivery vehicle footprint (37) with a horizontal extent equal to or less than the horizontal extent of the delivery vehicle grid cell (53);
16. The automated storage and retrieval system of claim 15. at least one of the plurality of delivery vehicle grid cells (53) of the delivery rail system (50) is disposed immediately below a container handling vehicle grid cell (122) of the container handling vehicle rail system (108);
17. The automated storage and retrieval system according to claim 15 or 16. Each of the first and second sets of rails (51, 52) of the delivery rail system (50) is a double track rail including two parallel tracks separated by a protrusion running intermediately.
18. The automated storage and retrieval system according to any one of claims 15 to 17. each of the first and second sets of rails (110, 111) of the container handling vehicle rail system (108) is a double track rail including two parallel tracks separated by a projection running intermediately;
19. The automated storage and retrieval system of any one of claims 13 to 18. the delivery rail system (50) extending from a location below the delivery port (150) to the second location;
20. The automated storage and retrieval system of any one of claims 14 to 19.