Storage systems and methods

A storage system having crash barriers is described. The crash barriers are mounted on separate structures, the structures being mounted adjacent the storage system. The separate structures include tracks such that robotic load handling devices operating on the storage system may over run without causing damage to the main part of the storage system.

The present invention relates to storage systems and methods. More specifically but not exclusively, it relates to robotic picking systems for picking objects from storage systems having storage bins in stacks, the stacks being located within a grid structure.

Some commercial and industrial activities require systems that enable the storage and retrieval of a large number of different products. One known type of system for the storage and retrieval of items in multiple product lines involves arranging storage bins or containers in stacks on top of one another, the stacks being arranged in rows. The storage bins or containers are removed from the stacks and accessed from above by load handling devices, removing the need for aisles between the rows and thereby allowing a large number of bins or containers to be stored in a given space.

Methods of handling containers or bins stacked in rows are well known in the art. PCT Publication No. WO2015/185628A (Ocado) describes a storage and fulfilment system in which stacks of bins or containers are arranged within a frame structure. The bins or containers are accessed by load handling devices operative on tracks located on the top of the frame structure. The load handling devices lift bins or containers out from the stacks, multiple load handling devices co-operating to access bins or containers located in the lowest positions of the stack. One form of robotic load handling device is described in PCT Patent Publication No. WO2015/019055 (Ocado) where each robotic load handler only covers one grid space of the frame work structure, thus allowing higher density of load handlers and thus higher throughput for a given sized system.

In some implementations of such container or bin handling systems, there can be a very large number of robotic load handling devices running on a single grid, the grid containing a large number of bins or containers in stacks. The robotic load handling devices may be running on the grid in close proximity to each other and often travelling at speed. Such storage systems are located within buildings that due to their size will often require the framework and grid structure to be built around structural members such as pillars supporting roof structures and other services.

Furthermore, in order to take full advantage of the space within the building, the framework and grid may be built so as to fill the available space, thereby requiring the grid to be located adjacent walls and other structures.

Moreover, for safety reasons in the event of malfunction, the edges of the grid and framework structure may require protection and the robotic load handling devices may need to be prevented from overshooting the edges of the grid.

According to the invention there is provided a storage system comprising: a first set of parallel rails or tracks and a second set of parallel rails or tracks extending transverse to the first set in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces; a set of uprights, the uprights and tracks together defining a framework; a plurality of storage containers arranged in stacks beneath the grid spaces, located beneath the rails and within the framework; at least one load handling device disposed on the grid, arranged to move laterally above the stacks on the rails, the load handling device comprising a lifting device arranged to lift one or more containers, or parts thereof, from a stack; wherein the system comprises an additional separate portion of framework comprising uprights with tracks mounted thereon, the additional separate portion of framework being located adjacent the storage system and in contact with the storage system, the additional separate portion of framework being further provided with barrier means, the barrier means extending over the tracks of the additional separate portion such that any load handling device over running the tracks of the storage system will continue to travel on to the tracks of the additional separate portion of framework and impacts the barrier, the forces generated by said impact being directed into the barrier and the separate portion and not being transmitted in to said storage system.

According to the invention there is provided a method of protecting a storage system, the storage system comprising tracks on which load handling devices are operable: providing a separate framework structure comprising tracks; mounting barrier means on the separate framework structure; locating said separate structure adjacent the storage system such that the tracks of the separate structure abut the tracks of the storage system, the barrier means extending toward the main storage system in a direction substantially parallel to the tracks.

Preferred features of the invention are defined in the claims.

As shown inFIGS. 1 and 2, stackable storage containers, known as bins10, are stacked on top of one another to form stacks12. The stacks12are arranged in a frame structure14in a warehousing or manufacturing environment.FIG. 1is a schematic perspective view of the frame structure14, andFIG. 2is a top-down view showing a single stack12of bins10arranged within the frame structure14. Each bin10typically holds a plurality of product or inventory items28, and the inventory items within a bin10may be identical, or may be of different product types depending on the application. Furthermore, the bins10may be physically subdivided to accommodate a plurality of different inventory items28.

In the description below, bins10will be used to denote containers intended for the storage of inventory items28, whilst delivery containers DT will be used to denote containers filled or intended to be filled to fulfil customer orders placed by customers. It will be appreciated that this terminology is used for ease of reference and explanation within this document. However, it should be noted that the bins10and the containers DT may be of the same shape and configuration. Furthermore, delivery containers DT may be stored in bins10within the storage system or any part thereof.

The frame structure14comprises a plurality of upright members16that support horizontal members18,20. A first set of parallel horizontal members18is arranged perpendicularly to a second set of parallel horizontal members20to form a plurality of horizontal grid structures supported by the upright members16. The members16,18,20are typically manufactured from metal. The bins10are stacked between the members16,18,20of the frame structure14, so that the frame structure14guards against horizontal movement of the stacks12of bins10, and guides vertical movement of the bins10.

The top level of the frame structure14includes rails22arranged in a grid pattern across the top of the stacks12. Referring additionally toFIGS. 3 and 4, the rails22support a plurality of robotic load handling devices30. A first set22aof parallel rails22guide movement of the load handling devices30in a first direction (X) across the top of the frame structure14, and a second set22bof parallel rails22, arranged perpendicular to the first set22a, guide movement of the load handling devices30in a second direction (Y), perpendicular to the first direction. In this way, the rails22allow movement of the load handling devices30in two dimensions in the X-Y plane, so that a load handling device30can be moved into position above any of the stacks12.

Each load handling device30comprises a vehicle32which is arranged to travel in the X and Y directions on the rails22of the frame structure14, above the stacks12. A first set of wheels34, consisting of a pair of wheels34on the front of the vehicle32and a pair of wheels34on the back of the vehicle32, are arranged to engage with two adjacent rails of the first set22aof rails22. Similarly, a second set of wheels36, consisting of a pair of wheels36on each side of the vehicle32, are arranged to engage with two adjacent rails of the second set22bof rails22. Each set of wheels34,36can be lifted and lowered, so that either the first set of wheels34or the second set of wheels36is engaged with the respective set of rails22a,22bat any one time.

When the first set of wheels34is engaged with the first set of rails22aand the second set of wheels36are lifted clear from the rails22, the wheels34can be driven, by way of a drive mechanism (not shown) housed in the vehicle32, to move the load handling device30in the X direction. To move the load handling device30in the Y direction, the first set of wheels34are lifted clear of the rails22, and the second set of wheels36are lowered into engagement with the second set of rails22a. The drive mechanism can then be used to drive the second set of wheels36to achieve movement in the Y direction.

In this way, one or more robotic load handling devices30can move around the top surface of the stacks12on the frame structure14, as shown inFIG. 4under the control of a centralised control utility (not shown). Each robotic load handling device30is provided with lifting means38for lifting one or more bins10from the stack12to access the required products.

The body of the vehicle32comprises a cavity40, the cavity40being of a size capable of holding a bin10. The lifting means38comprises winch means and a bin gripper assembly39. The lifting means lifts a bin10from the stack12to within the cavity40within the body of the vehicle32.

In this way, multiple products can be accessed from multiple locations in the grid and stacks at any one time.

The robotic load handling devices30remove bins10containing inventory items28(not shown) therein and transport the bins10to picking stations (not shown) where the required inventory items28are removed from the bins10and placed into bins10comprising delivery containers DT. It is important to note that a delivery container DT may fit within a bin10. The bins10may comprise inventory items28or may comprise delivery containers DT. Furthermore, the delivery containers DT may comprise at least one bag52, the inventory items28being picked directly in to a bag52at a pick station (not shown).

The empty bins10or the bins comprising delivery containers DT or the bins comprising delivery containers DT and bags52may all be stored within the stacks12. It will be appreciated that all the bins10have substantially the same external shape and configuration.

FIG. 4shows a typical storage system as described above, the system having a plurality of load handling devices30active on the grid above the stacks12.

FIGS. 1 and 4show the bins10in stacks12within the storage system. It will be appreciated that there may be a large number of bins10in any given storage system and that many different items28may be stored in the bins10in the stacks12, each bin10may contain different categories of inventory items28within a single stack12.

In one system described above and further in UK Patent Application Number GB1410441.8—Ocado Innovation Limited, hereby incorporated by reference, the storage system comprises a series of bins10that may further comprise delivery containers DT with customer orders contained therein or may further comprise bins10with inventory items28awaiting picking contained therein. These different bins10and combinations thereof may be contained in the storage system and be accessed by the robotic load handling devices30as described above.

FIG. 5shows a schematic perspective view of a separate portion of framework114comprising uprights116and tracks122in accordance with one form of the invention, the separate portion of framework114also comprising barrier means124. The barrier means124extend toward the main storage system and are substantially parallel to the direction of the tracks122in the separate portion of framework114.

The structure of the separate portion of the framework114is attached to the floor of a building (or level within a building) containing the storage system. However, the separate portion of framework114is not fixedly attached to the main storage system.

The barrier124comprises any material or structure that may act as a crumple zone in the event of an impact from a robotic load handling device that has overrun the tracks of the main storage system due to malfunction or error in the system.

For example, the barrier may comprise a metallic honeycomb type structure, or an inflatable barrier, a barrier formed from any suitable resilient material such as padding or foam or rubber. The barrier may further comprise mesh or wire or tensioned cables or structures or materials. It will be appreciated that any structure, material or device capable of absorbing the forces generated by a load handling device impacting the barrier124may be used and need not be limited to the examples given above.

FIG. 6is a schematic perspective view of two of the separate portions of framework114ofFIG. 5, the first separate portion114abeing located adjacent a first edge of the storage system ofFIGS. 1 to 4and extending in the X direction, the second separate portion114bbeing located adjacent a second edge of the storage system ofFIGS. 1 to 4and extending in the Y direction of the main storage system.

As can be seen inFIG. 6, the tracks122of the separate portions of framework114do not comprise whole grid squares.

FIG. 7is a further schematic perspective view of the storage system ofFIGS. 1 to 4with the separate portions of framework extending along the X and Y axes of the storage system. As can be seen inFIG. 7, the separate portions of framework114may be supported on a mezzanine structure126.

In use, the separate framework114is positioned adjacent an edge of the main storage system such that the tracks122of the separate portion abut the tracks22of the main storage system. Suitable resilient material may be located between the tracks122and the tracks22. The edge of the main storage system may be the part of the storage system adjacent the edge of the building in which the system is located. However, it will be appreciated that the separate portion of framework114may be positioned any part of the main storage system where the movement of the robotic load handling devices may over run the grid of the main storage system and potentially impact and damage other parts of the building such as structural support members, pillars, walls, partitions and the like.

Should a robotic load handling device malfunction and overrun the main storage system, it will impact the barrier structure124. As the robotic load handling devices may be travelling up to 4 metres per second and weigh in the region of 200 kg, it will be appreciated that such an impact will generate a substantial force on the barrier and the separate portion of framework114.

As the separate framework structure114is not fixedly attached to the main framework structure14, the barrier124attached to the separate structure114absorbs the energy of the impact and may deflect. However, it will be appreciated that the barrier may not absorb all of the energy of the impact and forces may be transmitted to the framework of the separate portion. However, as the separate portion114is not attached to the main framework14, no forces will be transmitted to the main storage system and any damage as a result will be limited to the separate portion of framework114which is easily replaceable.

It will further be appreciated that whilst many of the above embodiments are described with reference to a main storage system, this definition is used for clarity purposes within the description. It will be appreciated that there may be several portions of framework within the main storage system, but all may be attached together. The separate portion of framework114is distinguished in that it is not fixedly attached to any part of the storage system comprising containers or bins10located in stacks12beneath the tracks22.

Whilst the foregoing description refers to a storage system it will be appreciated that the function of the system may not solely be storage of items or goods. For example, the system may be used to store empty bins awaiting items to be placed therein, or bins comprising customer orders temporarily located within the framework as well as containers10comprising goods or items being stored.