Carousel for the warehousing of goods

Rack (1) for the dynamic warehousing of goods boxed in containers (S), of the type including at least one bidirectional conveyor device (2) for the containers (S); and at least some means of inversion (4 and 4a) of the movement and connection of conveyor devices (2), the means (4) of inversion of the movement (4) being fitted with variable-geometry guiding means (6), movable between an open operating position (A) and a closed position (B); the means (4) of inversion of the movement including at least one rotating disc (12) capable of transporting the containers (5) along a substantially semicircular path corresponding to the closed operating position (B).

The present invention relates to a rack for the warehousing of goods. In particular, the present invention relates to a rack for the warehousing of goods usable advantageously for the dynamic warehousing of goods located inside containers, for example crates, boxes or similar, of which the description which follows will make specific mention without thereby losing in generality.

BACKGROUND TO THE INVENTION

In general, motorised racking systems have been known for some time, capable of storing goods dynamically.

These racking systems are capable of setting the stored goods in motion until they present a sought object at a picking station from which it can be taken.

In general, the techniques of moving the goods most widely used are those in which the goods are arranged inside containers or boxes which are made to circulate freely by means of, and on, conveyor devices.

In the case of storage on conveyor devices, it is desirable to use systems for dynamic identification of the moving objects, for example of the type using barcodes, magnetic code, transponders or similar, which is not however required for fixed racks where it is sufficient to store in a database the location where the item has been placed.

Currently, motorised racking systems are known of the type with a single track, which are capable of carrying out a service analogous to racking systems of the gravity type, i.e. capable normally of housing only a single type of article or goods in movement.

In this case the picking sequence is a predefined sequence to define a system of warehousing usually identified by the acronym LIFO (last in, first out: the last to come in is the first to go out) if access is from a single side; or on the other hand with the acronym FIFO (first in, first out): the item which came in first is the first to go out) if the loading of the boxed goods takes place on one side while unloading takes place on a different side.

Racking systems of these types are for example described and illustrated in the International Patent application PCT no. WO 02/074663 and in United States patent application no. US 2003/152446.

Motorised racks of the recirculating type are also known, including a system of conveying in a loop in which the stored goods can move in a closed circuit or loop and therefore present themselves selectively at a pre-established station, from which it is then possible to carry out the loading of new boxed goods or the unloading outwards of goods previously warehoused in the said racks.

These types of recirculating racks in general include parallel linear conveyors provided with 180° curves at the ends, and are characterised by a constant high-speed motion, and therefore allow rapid operations of search and identification of objects, although for the extraction of the objects themselves, complicated devices are necessary which require manipulation techniques; furthermore, the above-mentioned curves necessitate relatively large dimensions and are therefore cumbersome.

Racking systems of these types are for example described and illustrated in Japanese Patent application no. JP 1.122.814 and in U.S. Pat. No. 3,303,918.

Other types of motorised racks currently known are defined by conveyor means arranged side by side, capable of moving the boxed goods in opposite directions. In these racks, there are means of stopping and means of lateral transposition capable of allowing the movement of the boxed goods.

These racks, as for example those described and illustrated in International Patent application no. WO 99/35061, in Japanese patent application no. JP 1.321.205 and in U.S. Pat. No. 3,662,905, have the advantage of being of compact dimensions, with structurally simple exit/entry portions for the goods, but have extremely low productive speeds of recirculating movement because of the continual stops and transposing movements.

SUMMARY OF THE PRESENT INVENTION

The present invention relates to a rack for the warehousing of goods. In particular, the present invention relates to a rack for the warehousing of goods usable advantageously for the dynamic warehousing of goods located inside containers, for example crates, boxes or similar, of which the description which follows will make specific mention without thereby loosing in generality.

An object of the present invention is to eliminate the disadvantages of the known art documented above.

According to the present invention a rack is created for the dynamic warehousing of goods boxed in containers, of the type described with reference to at least one of the claims which follow.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

With reference to the attached figures, no.1globally indicates a motorised rack for the warehousing of goods (not illustrated), which are located inside containers or boxes S in motion along an annular path.

Rack1, including at least two bi-directional conveyor modules2, each of which is rectilinear (without this representing a limitation to the present invention), is provided with respective conveyor rollers3(FIGS. 1 and 2). The modules2are connected to each other by motion-inverting devices which for simplicity will be designated curves, and which are connected to modules2by operating stations facing each other: these will be designated entry station SI or exit station SU depending on the current direction of advancement of containers S along the annular path. In accordance with an anticlockwise direction of advance inFIG. 1, the entry station SI is located to the left of an ideal median longitudinal plane I located between the two modules, and the exit station SU is located to the right of this centre plane. This plane I is visible only with reference toFIG. 2.

Still with reference toFIG. 1, rack1includes a tail-end/recirculating curve4afitted with fixed lateral guides5and a head-end curve4fitted with end guides6movable between an open operating position A (FIG. 4), to allow the exit or entry of boxed goods, and a closed position B (FIG. 5). Both curves,4and4a, are structured to cause the inversion of the movement of the boxes S through 180° around a determinate vertical axis Z, located in a position substantially central to the ends of rectilinear modules2.

According to what is illustrated inFIG. 2, the module2has a determinate length, and includes two side longitudinal members7, one central longitudinal member8, located in line with the longitudinal median plane I, and at least four cross-pieces9which have the function of rigidly supporting said central longitudinal member8and (in freely rotatable manner) a longitudinal shaft10, through a plurality of bearings known and not illustrated.

The side longitudinal members7and the central longitudinal member8are capable also of defining respective containment guides for the box containers S.

A solution is used called “LINE SHAFT DRIVE” which consists of the longitudinal shaft10which transmits the movement to a plurality of independent polyurethane belts C visible only inFIG. 22, each one of which is capable of effecting the rotation of a respective conveyor roller3through a clutch transmission of known and not illustrated type.

The longitudinal members7and8and the cross-pieces9are advantageously slotted together and suitably bolted to define a frame T, while rollers3are provided in known and not illustrated manner with a spring-loaded pin at the end to allow rapid assembly without the need for special tools.

The presence of a single central shaft10has the following advantages:

i) structural advantage, central shaft10can be placed above longitudinal central member8which runs between containers S, and can therefore be located between the moving containers S themselves.FIG. 22demonstrates the advantage of the reduction in height, whileFIG. 23shows how it is possible to carry out manual extraction of box S.

ii) economic advantage, since in order to contain costs and thrusts, a very wide spacing between rollers3is used, preferably 150 millimeters with the rollers having a diameter of at least 40 millimeters. Where it is thought necessary, even diameters of 50 millimeters are permitted, without this being assumed as a prescription which limits the protective scope of the present invention. With reference toFIGS. 4 and 5, curve4has been enlarged to allow the rotation through 180° of boxes S around the respective axis Z, and is equipped with a central guide11, and a central drum20carried idly coaxially with axis Z itself with the function of internal guide to curve4, to describe two adjacent parallel tracks which function as a continuation of the two adjacent modules2. Curve4, furthermore, includes fixed lateral guides5located on the outside and head-end guides6, manoeuvrable through a switching device K better visible inFIGS. 10,14and15, to allow access for entry and exit of containers S to and from rack1, with configuration variable between an operating position A visible inFIGS. 4 and 6and a position B visible inFIGS. 5 and 7. In particular, head-end guides6are curved and capable of connecting to external lateral guides5, and they create a substantially circular edge.

The curve4is sized radially in such a way as to present transverse dimensions of two modules2side by side, and has conveyor components in common with the modules2themselves, i.e. the rollers3A functionally operated by belts C through shaft10, and bearings known and not illustrated.

The curve4includes a rotation disc12(FIGS. 4 and 5, and10to13), preferably made of metal, supported by frame T in line with a vertical axis X of rotation laterally displaced with respect to axis Z by a determinate distance so as to move containers S along a semicircular path when, in use, guide6is located in above-mentioned operating position B. Furthermore, axis X is displaced with respect to axis Z of rotation of drum20, on the opposite side of the modules2.

It will be noticed that disc12is located in a central position between a plurality of realigning rollers3A of reduced length, parallel to and substantially coplanar to rollers3, and located at the exit from curve4according to an anticlockwise direction of advancement of boxes S with reference toFIGS. 6 and 7, to make containers S resume their rectilinear trajectory without impacting central guide11. Such rollers3A are missing only in a portion localised to ¼ of the circular path prescribed for boxes S on disc12according to an anticlockwise circular trajectory inFIGS. 6 and 7. The operation of curve4is based on rotating disc12which, in accordance with position B, moves containers S, carrying them on the return track with a rotation of 180° along the above-mentioned semicircular path, according to the flow of movement illustrated inFIGS. 8 and 9. The reduced length of rollers3A allows the latter to cooperate with disc12in supporting each box S only partially, in such a way as to make possible the gradual variation in speed of the boxes at the inversion of the movement between the preceding and the subsequent modules2. It should be noted that the displacement of axis X with respect to axis Z is arranged laterally by an amount equal to half the length of rollers3A.

On the other hand, the modules2present a zone with a greater density of rollers3(preferably double) immediately upstream and downstream of rotating disc12, in such a way as to increase the dragging effect on boxes3both in entry and in exit from head-end curve4.

Preferably but without limiting effect, the rotating disc12can be formed in a single piece by moulding, and has a low thickness so as to be sufficiently flexible and always rest on castors21, carried by frame T. The castors21will be better described below, and are visible inFIGS. 10 and 13. The disc12can be provided with radial ribs13and a stiffening edge and adapting chamfer facing downwards.

The disc12is coupled mechanically to a transmission including a reducer14carried by frame T, and is gripped between two clutch discs (FIGS. 10,11) for limiting the thrust. The disc12, furthermore, rests at its periphery on six castors21, installed in such a way as to be adjustable in height in a known and not illustrated manner, for the purpose of linking up correctly a plane defined by an upper generating line of rollers3and3A with the plane of disc12itself. The reducer14takes its motion directly from a reduction motor M coupled mechanically to the central shaft10by means of a shaft delimited longitudinally by cardan joints. The transmission ratio of reducer14is such as to confer on disc12a peripheral speed at the average radius equal to about double the speed of advancement of the boxes S on modules2. It will be noticed that reduction motor M is the only actuator provided for the activation of rollers3, rollers3A and disc12on rack1. In fact, the reduction motor M is connected to disc12by means of reducer14and to rollers3and3A by means of the above-mentioned belts22.

With particular reference toFIGS. 6 and 7, in use, rollers3A feed boxes S towards the receiving module2at a speed of advancement equal to 1.5 times the feed speed of the boxes themselves on rollers3of modules2. The boxes S are therefore fed onto disc12which accelerates them to a speed double the feed speed, and then they are slowed down by rollers3A to a speed which is 1.5 times the feed speed given by rollers3, to then slow down further on rollers3. The reason for these variations in speed is as follows: boxes S must be separated from each other. Once transferred onto disc12, each box S slides towards the outside because of the difference in centres of rotation between disc12and drum20. This sliding towards the outside causes, initially, a further increase in speed since box S is moving towards greater radii. In the last part of its rotation through 180°, the box S, which has been pushed beyond the edge of the disc by the central idler drum, meets the slowing rollers which realign it with the bi-directional conveyor. Guides5,6and11have sufficient vertical extension and robustness to contain the thrust of containers S which is generated when these are arrested by blade16against the forward thrust produced by rollers3of the module which feeds containers S onto curve4. Reduction motor M is located between internal guides11and has a lesser overall vertical dimension than guides5,6and11, and reducer14has a limited vertical extension. This makes each rack1particularly limited in height and suitable for stacking, taking up little room vertically without creating restrictions on the forward movement of the boxes S on the rack1below.

According to what is illustrated inFIGS. 16 to 20, the rack1is furthermore provided with a blocking device15located at picking station ST, including the transverse blade16, supported rotatably around an axis parallel to rollers3by two relative lateral flanges30. This blade16is interposed between two consecutive rollers3of the receiving module2, and has overall dimensions such that it can be inserted between the two mentioned rollers3, so as to spring up to engage a free space between two consecutive boxes S, in such a way as to block the advance of the box S which follows, according to the modality of advancement of the two boxes S in question. For this purpose, the blocking device15includes a frame19provided with two brackets40connected to each other by a crosspiece42, capable of synchronising the rotation of brackets40with respect to longitudinal members7and8which, respectively, support them freely rotatably around an axis parallel to rollers3and located below the running plane of rollers3. Each bracket40carries rotatably a respective flange30of blade16, which presents, in its turn, at least one tappet32, which engages sliding a slot34formed in one of the brackets40to guide blade16itself in rotation, and to limit its respective rotation with respect to brackets40. Between each flange30and the respective bracket40, an elastic connection is provided which includes a torsion spring36, suitable for keeping said flange with its respective tappet32adjacent to an upper end of slot34, and selectively deformable by the bottom of a box S. Blocking device15also includes at least one actuator18capable of imparting a rotation to frame19around a respective axis44parallel to rollers3from a starting position P through an angle sufficient to position blade16into an activation position P′, in which this blade16occupies the space below the running plane of rollers3, provided that this plane is unencumbered by boxes S. In position P′, blade16brushes the bottom of the corresponding box3causing the torsion of spring36, until the condition occurs in which the running plane of boxes S themselves becomes free. It will be noted that inFIGS. 17-20the reference number18has been used for convenience to indicate the thrust component of actuator18, referring to the respective capacity for moving frame19around axis44, without this being able to cause prejudice to the description itself.

In use, as soon as the activation of actuator18is commanded, the frame19is rotated in such a way as to push blade16into the position visible inFIG. 18in contact with the bottom of a box S, in which the spring36is deformed so as to arm blade16advantageously in advance, in such a way as to make it ready to spring up once box S itself has passed (FIGS. 19 and 20), for the purpose of blocking the advance on rollers3of the box S which follows in the direction of advance.

The electronic management of each rack1is entrusted to an electronic panel QE, located close to head-end curve4, and including electrical and electronic components visible inFIG. 21. The electronic system governing rack1(seeFIG. 21) memorises the order in which containers S are kept, in order to prearrange the intervention of blocking device15. Adjacent to the head-end curve4, therefore, we find the reduction motor M, the blocking device15, the switching device K, and a code reader CR, in the event that the boxes S carry codes. The achievement of this result is made possible by the rollers3, clutch driven at low thrust, for the correct performance of the containment guides at the curves4.

In conclusion, rack1, the subject of the present invention, has the following characteristics:conveyor lines (outward and return) side by side for minimum transverse overall width;each recirculating curve4is such as to allow continuous recirculation between adjacent tracks. The width dimensions of the curves are comparable to those of two rectilinear conveyor modules2side by side;each curve4is fitted with guides with variable geometry which allow simultaneous access for loading and unloading at the head-end from the same side, in order to allow the racks to run alongside each other;each box's entry to and exit from rack1is effected solely through movement on rollers;each rack1has minimum overall height to allow vertical stacking with a high rate of exploitation of the available volume, and therefore without waste of space;the construction of each individual rack, and of warehouses fitted with a plurality of racks is modular, inexpensive and highly reliable;silent and collision-free operation;operation which does not require maintenance or lubrication for maximum cleanliness of the goods;independent electronic management for each individual rack1.

The operation of rack1described above is clear from the above description, and does not require further explanation.

Finally, it is clear that modifications and variations may be made to rack1here described and illustrated without for this reason departing from the protective compass of the present invention.

It will be noted that curve4ais structured similarly to curve4, simplified by the fact of not including movable guides6and therefore it has the same function as the curve4having the movable guides6in the respective position B.

Naturally, the fact that axis X is displaced with respect to axis Z on the side of one of the two operating stations and on the opposite side of modules2, renders the rack more efficient for a determinate direction of advance of containers S on rollers3and on disc12. In particular, the advantages of rack1described above may be encountered when the direction of advancing movement of containers S locates station SI (for entry to curve4) on the side of axis X, but for reduced speeds, the rack1can operate correctly even if activated in the opposite direction.