Robotic parking device and handling method

A robotic parking device is described. The device includes a number of stacks of containers as shown in FIG. 3, the stacks being positioned within a frame structure including uprights and a horizontal grid disposed above the stacks, the grid having substantially perpendicular rails on which load handling devices can run. Cars or vehicles are positioned in containers that are moved in to and out of the stacks by the robotic handling devices running on the grid. The cars are put in to the grid at entry points that may be positioned at points under the stacks.

The present invention relates to a robotic parking system device and method. More specifically but not exclusively, it relates to how an established technology for order picking and sortation of smaller items can be scaled up to create a high density, high throughput parking system.

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 accessed from above, removing the need for aisles between the rows and allowing more containers to be stored in a given space.

There are over one billion cars in the world and most of them are parked at any given point in time. In many cities and other locations, car parking requires a substantial percentage of the available land, which has led to the evolution of the multi-storey car park. Due to the need to random access to all of the cars, restrictions imposed by varying sizes of vehicles, structural needs of the buildings and the need for drivers and passengers to comfortably access their vehicles, such car parks do not fully utilise the available volume for parked cars. In fact, only around 10% of the volume of a typical multi storey car park is actually filled with the volume of cars. The present invention seeks to increase that number to around 40%.

Methods for parking vehicles more densely using mechanical devices exist as described in patent applications EP0740034 A1 and DE10151916 A1 or patents U.S. Pat. No. 3,390,791 and EP2663703 B1. The Otto Wöhr Company claims to have delivered over 400,000 mechanised parking locations globally over the years. Such systems allow more density than a conventional multi storey garage, but have some significant drawbacks. These include cost, reliability and throughput capacity. These factors have therefore made them difficult to justify in many situations. The present invention uses a completely different principle to address these drawbacks.

Methods of handling containers stacked in rows are well known. In some such systems, for example as described in U.S. Pat. No. 2,701,065 Bertel, comprise free-standing stacks of containers arranged in rows in order to reduce the storage volume associated with storing such containers but yet still providing access to a specific container if required. Access to a given container is made possible by providing relatively complicated hoisting mechanisms which can be used to stack and remove given containers from stacks. The cost of such systems are, however, impractical in many situations and they have mainly been commercialised for the storage and handling of large shipping containers.

The concept of using freestanding stacks of containers and providing a mechanism to retrieve and store specific containers has been developed further, for example as described in EP 1037828 B1 (Autostore), the contents of which are incorporated herein by reference. This describes a system in which stacks of containers are arranged within a frame structure. Robotic load handling devices can be controllably moved around the stack on a system of tracks on the upper most surface of the stack.

One development of load handling device is described in PCT Application No GB2014/052273, where each robotic load handler only covers one grid space, thus allowing higher density of load handlers and thus higher throughput of a given size system. As described in GB Patent Application No 1506364.7, containers may also be of varying heights and sizes.

According to the invention there is provided a robotic parking system comprising a plurality of vehicle holding containers, the containers being disposed in stacks within a frame work structure, the frame work structure comprising a series of substantially vertical uprights having a substantially horizontal grid mounted thereon, the grid comprising two substantially perpendicular sets of rails on which at least one load handling device is operable, the load handling device comprising a body mounted on wheels, a first set of wheels being arranged to engage with at least two rails of the first set of rails, the second set of wheels being arranged to engage with at least two rails of the second set of rails, the first set of wheels being independently moveable and driveable with respect to the second set of wheels such that when in motion only one set of wheels is engaged with the grid at any one time thereby enabling movement of the load handling device along the rails to any point on the grid by driving only the set of wheels engaged with the rails in which the containers comprise a vehicle carrying platform and supports, the supports positioned and sized such that each container supports the container immediately above in the stack.

The key benefits over the prior art of conventional multi-storey car parks is much higher density of parking. Around four times more vehicles should be achievable. Additionally, it will be much faster than driving up and down several levels of multi storeys and there would be less risk of damage to the vehicles. The key benefits over prior art mechanised car parks are cost, since the load handlers would on average be much better utilised than the cranes of the prior art systems, for any given maximum throughput capacity. It would be reliability, since the system could easily be designed so that any one load handler breaking down would not prevent access to any of the vehicles. Moreover, the present invention would improve space utilisation, by up to a factor of two.

FIG. 1shows a stackable container10, the container10carrying a vehicle20. The container10comprises4corner supports30, a container base35and side barriers40. The corner supports are moveable around a pivot point at the join with the base35such that the corner supports can fold down, as shown inFIG. 2, to allow easy movement and positioning of the vehicle20within the container10. As shown inFIG. 3, the side barriers40are collapsible to allow easy entry in to the vehicle20from the container10.

It will be appreciated that the word “container” is used here for a device which is primarily a platform with four heavy corner uprights30to support other containers10on top and sidings40especially on the short sides to ensure a vehicle20can never roll off the container10or any person accidentally left inside a vehicle20can get out of the vehicle20and in to danger. However it will be appreciated that the container10may be of any suitable form that is capable of carrying a vehicle20and supporting other containers10carrying vehicles20in a stack110.

For example, in another embodiment of the invention the container10may comprise a platform having lowerable upturned sides and a cage or box structure that may be lowered over the vehicle20, thereby completely enclosing the vehicle which may be advantageous for safety reasons.

In use, a plurality of containers are stacked on top of one another to form stacks110. The stacks110are arranged within a frame structure70.FIG. 4shows stacks110each comprising five containers10, the device100comprising a 6 by 3 block of stacks110within the frame structure70. The frame structure70comprises a series of upright members72that support horizontal members74a,74b. A first set of substantially parallel horizontal members74ais arranged substantially perpendicularly to a second set74bof substantially parallel horizontal members to form a horizontal grid structure74supported by the upright members72.

The members72,74are typically manufactured from metal. The containers10are stacked between the members72,74of the frame structure70, such that the frame structure70guards against horizontal movement of the stacks110of containers10, and guides vertical movement of the containers10.

The top level of the frame structure70includes rails74arranged in a grid pattern across the top of the stacks110. Referring toFIGS. 4, 5 and 6, the rails74support a plurality of robotic load handling devices50. A first set74aof parallel rails74guide movement of the load handling devices50in a first direction (X) across the top of the frame structure70, and a second set74bof parallel rails74, arranged substantially perpendicular to the first set74a, guide movement of the load handling devices50in a second direction (Y), substantially perpendicular to the first direction. In this way, the rails74allow movement of the load handling devices50in two dimensions in the X-Y plane, so that a load handling device50can be moved into position above any of the stacks110.

Each load handling device50comprises a body55which is arranged to travel in the X and Y directions on the rails74of the frame structure70, above the stacks110. A first set of wheels34, consisting of a pair of wheels34on the front of the body55and a pair of wheels34on the back of the body55, are arranged to engage with two adjacent rails of the first set74aof rails74. Similarly, a second set of wheels36, consisting of a pair of wheels36on each side of the body55, are arranged to engage with two adjacent rails of the second set74bof rails74. 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 rails74a,74bat any one time.

When the first set of wheels34is engaged with the first set of rails74aand the second set of wheels36are lifted clear from the rails74, the wheels34can be driven, by way of a drive mechanism (not shown) housed in the body55, to move the load handling device50in the X direction. To move the load handling device50in the Y direction, the first set of wheels34are lifted clear of the rails74, and the second set of wheels36are lowered into engagement with the second set of rails74b. 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 devices50can move around the grid at the top of the stacks110on the frame structure70under the control of a central picking system (not shown). Each robotic load handling device50is provided with means for lifting out one or more containers10from the stack110to access the required vehicle. Using multiple load handling devices50enables access vehicles20from multiple locations in the grid and stacks110at any one time.

In use, a vehicle20is manoeuvred into a container10at an entry point and the driver exits the vehicle20. The corner supports30and side barriers40are raised and a load handling device50is instructed by a control system (not shown) to collect the container10and position it within the stacks110of containers10.

The control system decides on the optimal point the vehicle should be positioned in the stacks110. If the vehicle20is not required for a long period of time, it may be advantageous for the container10to be laced underneath containers10holding vehicles20that are needed more imminently. Therefore, the load handler50may move containers10already in the stacks110in order to create a position to place the container10holding the new vehicle20to be parked. Once a suitable position is created, the load handler50is positioned on the grid74at a point where it can pick up the container10. The container10is lifted to within the body55of the load handler50and the load handler50is moved to a position on the grid74immediately above the position where the container is to be placed in a stack110. If necessary, other containers10are back placed above the recently positioned container10.

It will be appreciated that several load handlers50may need to work in cooperation to move containers10around in the stacks110. Furthermore, load handlers may rearrange the stacks periodically in order to position vehicles20near the tops of the stacks110that will be needed soonest.

When a vehicle20needs to be retrieved from the stacks110, a load handler50is positioned above the relevant stack110and removes the top container10. If this container10holds the desired vehicle20, the container10is moved to the exit point. If the container10does not contain the desired vehicle20, the container is moved to an alternative stack110and the next container in the first stack110is accessed. This continues until the container10holding the desired vehicle20is retrieved. This container10is then moved to the exit point for collection.

In this way, a high density of vehicle packing is achieved, whilst easy deposit and retrieval of vehicles is maintained.

It will be appreciated that a control system, not shown, is provided with suitable means for identifying and monitoring which vehicle20is in which container and where in the stacks110it is located. The control means may use number plate recognition or may use a ticketing and bar coding system or any other suitable tracking means

It will be appreciated that there is a grid structure to support the containers10horizontally. This means that the containers10can be designed for the corner supports30to take the vertical forces from the containers above, but do not need to take any horizontal forces. This way highly stable stacks110can be made from low cost containers10.

It will be appreciated that vehicles20will be loaded into and out of containers10at dedicated entry and exit points. Examples of these entry and exit points are shown inFIGS. 7 and 8. As shown inFIGS. 7 and 8, the entry and/or exit points comprise an area where the container10is received from the load handling device50. The entry and/or exit point may comprise additional barriers or fencing to protect users when the container10is being received from the load handling device50.

In a further embodiment of the invention, the container10has one or two folding short sides incorporating the corner supports, which can be used as ramps to drive on and off, but will also allow the container to be as narrow as possible, since the vehicle will not need to be driven in between the load carrying pillars at the corners.

In yet another embodiment of the invention the long sides of the container are arranged so that they enable driver and passengers to open the doors at entry and exit stations, when either of the short sides are down. When the short sides are up, the long sides will provide a barrier, so that no doors can be opened. This to prevent a person who accidentally gets left inside a vehicle from getting into danger.

In a further embodiment, there is a heat or other sensor to ensure that no person or animal is left inside the vehicle before the container is closed.

In a further embodiment the driver of the vehicle20communicate with the parking system via a communication device such as a smartphone to set and modify the time to access the vehicle.

In yet another embodiment, the driver can specify a certain airplane or train on which he is travelling, and the parking control system can communicate with the air or train traffic control systems to estimate when the vehicle will be required.

In another embodiment of the invention, the priority of different drivers waiting for their vehicles can be set depending on how much they pay for the parking.

In a further embodiment, there are containers10of different heights and/or sizes to maximise space utilisation when there are vehicles of significantly different heights.

In another embodiment, there are two or more sizes of containers and load handlers for situations where a significant proportion of the vehicles are substantially smaller than others, the stacks110being arranged such that there are subsections of the system dedicated to differently sized vehicles.

In a final embodiment, automatic number plate recognition is used at the entry to the facility to get information about the model of vehicle, so that the driver can be directed to an appropriate entry station.

It will be appreciated that as each container supports the container10above it in the stack110each container10must be able to support the weight of the maximum number of containers10when fully laden with vehicles20that may be held in the stack110. It is therefore important that the structure of the container is designed to accommodate such vertical forces.

In the embodiments described above, the container10comprises structural corner supports30mounted on a flat base35. However, it will be appreciated that any suitable form of container10may be used that is capable of supporting laden containers10in the stack110above it.

As shown inFIGS. 9 to 11, the container11comprises a platform35and a box-type lid structure80. It will be appreciated that in this embodiment, the box-type structure80would need to be able to support similarly configured containers11above it in the stack110. This may require solid sides to be used for the box structure80or may require corner supports30to be used with a cage like box structure mounted thereon.

In use, the vehicle20is parked on the substantially flat base35. Once the driver and any passengers have exited the vehicle20, a box-like structure is lowered over the vehicle. The box-like structure80comprises four load carrying supports30in the corners and solid and/or mesh sides and roof, as required for stability and protection. The box-type structure80is removably attached to the base35in order to allow the container11to be moved within the parking system. The container11, base35and box-type structure may be formed from steel, either solid sheets or mesh either in total or in combination. However, it will be appreciated that any suitable material may be used.

In a further embodiment of the invention, shown inFIGS. 12 to 14, an alternative mechanism for inputting vehicles in to the robotic parking system is shown.

As shown inFIG. 12, the alternative mechanism comprises a plate moveable mounted on a set of rollers100. The plate135may be moved from a first position to a second position on the rollers100. The rollers100may be driven by an appropriate driving mechanism. In the first position, the plate135is positioned such that a vehicle may be located thereon. In the second position, the plate135is positioned within a box-type structure180comprising at least corner supports. The box type structure180may comprise sides formed from a solid panel or a mesh type structure formed from any suitable material but preferably a structural metallic material. Preferably the box-type structure comprises solid sides so as to protect the robotic parking system, other vehicles and operatives, from fire within the box once the vehicle is parked.

The roller mechanism100within the box180is provided with rollerless recesses. The underside of the plate135is provided with cooperating means to interact with the rollerless recesses in the base of the box180.

The plate135, when in the second position within the box-type structure locates in recesses within the roller mechanisms100in the base of the box. The recesses within the roller mechanism100enable the plate135to releasably locate at a fixed position within the box180. Furthermore, the weight of any vehicle on the plate135will cause the plate135to locate in such a manner that the vehicle cannot move once the box180is lifted by the load handling device50.

The mechanism by which the plate135and the roller mechanism interact is more clearly shown inFIGS. 13ato 13c.FIG. 13ashows the plate135in the second position in which the plate is fully located within the box180and securely positioned.FIG. 13bshows in greater detail the recesses in the roller system100that allows the plate135to correctly move and repeatedly locate in a secure position within the box180.

FIG. 13cshows the plate135in the second position where the again the plate135is entirely within the box and the underside of the plate135is located such that the rollerless recesses in the base of the box185are located against cooperating portions of the plate135.

As shown inFIG. 15, the density of parking achieved by the robotic parking system exceeds that of a standard multi storey car park as no entry and exit ramps or aisles are required.

In use, as shown inFIG. 14, a vehicle20enters through an open gate in to an entry point. The vehicle20is positioned on the plate135, the plate135being located on the roller mechanism in the first position. Doors192to the parking system are closed. The driver and passengers exit the vehicle and the system through the doors190. Once the doors190are closed, the doors192may open and the roller mechanism activates to move the vehicle located on the plate135in to the box180. The plate135is driven on the rollers via any suitable drive system until the plate locates in the rollerless recesses in the base of the box180. At this point the plate135will no longer move with respect to the box180and the vehicle is correctly and securely positioned within the box180.

Once in the second position within the box, the door192will shut and the plate135will be substantially sealed against the base of the box180. In this way, should there be any ignition of fuel within the box, no adjacent vehicles will be damaged and the fire may be contained within one box180.

Once the box180is sealed the load handling device will be moved in situ and the box containing the vehicle will be lifted and positioned within a stack within the parking system. It will be appreciated that the box can be identified by suitable identification means and that the box180may be positioned with the stacks dependent on the length of time the vehicle is expected to remain within the car park.

In order to remove the car from the car park, the position of the box containing the target vehicle is identified and the load handling devices, either individually or in concert act so as to retrieve the target box180from within a stack within the system. Once retrieved by a load handling device50, the box is returned to the entry/exit point of the car park where the box is deposited in the exit area. Once the doors192are opened, the roller mechanism acts in reverse to move the plate135from the second position within the box to the first position where the vehicle can be collected. Once in the first position, the door192closes and the driver can enter and retrieve the vehicle.

It will be appreciated that the plate135will need to be lifted so as to overcome the secured positioning of the plate135within the rollerless recesses within the box180. This may be achieved by any suitable means but these may include providing a lifting mechanism operable to lift the plate135only once the box is located fully in the exit position.

Once in the exit position with the door192closed, the door190may open to allow the vehicle to exit.

Each box180may be provided with sprinkler means to extinguish any fire in the event of an emergency. It will be appreciated that the water or fire retardant fluid may be routed in to the box180via pipework mounted on or within the uprights72of the framework or the horizontal structural members74. When not in use, the sprinkler pipes remain empty. In this way, leakage of water or fire retardant fluid is minimised.

When located within the box180, the plate135may define a cavity enabling liquids such as oil, rain water and melted snow plus other road debris may collect in the cavity. The cavity will be sealed such that no liquids or debris leak on to vehicles or boxes180below. Furthermore, the cavity may be periodically cleaned in response to a signal from sensor means located within the cavity indicating that cleaning is required.

In the event of a fire being detected, only the boxes180in the given stack or the individual container containing the fire need be sprinkled. The box type structure may be sealed sufficiently to prevent the spread of fire due to lack of oxygen.

Other services may be routed to boxes in a similar manner. For example sensors may be located within the boxes180to monitor temperature, humidity, vibration, movement. Furthermore, camera means may be provided within each box to allow the car park operator to monitor the vehicles contained within the stack. All of these sensor mechanisms require power and may require data logging means. All such services and communication means may be routed to each box180via the uprights72of the framework or may be routed via the boxes180themselves.

UK Patent Application Nos GB1518091.2 and GB1518115.9, from which the present application claims priority, detail systems and methods of routing services through containers and framework structures and are hereby incorporated by reference.

It will be appreciated that the load handling devices50must be capable of lifting and moving laden containers. However, any suitable form of winch mechanism capable of lifting a laden container10,11up and within the body55of the load handler50may be used.

It will be appreciated that the mechanisms described above are exemplary only and a skilled person in the art may be able to propose alternative mechanisms.