Patent Publication Number: US-2021171285-A1

Title: Modular storage and order picking system

Description:
FIELD OF THE INVENTION 
     The invention relates to a modularly constructed storage and order picking system for articles stored in containers, and to a method for constructing and commissioning said system. 
     BACKGROUND OF THE INVENTION 
     For Internet-based mail-order businesses (e-commerce), flexible, fast and reliable logistics are essential. Said logistics include storage and order picking systems which collate the individual customer orders, package them, and prepare them for dispatch. 
     The need for storage and order picking capacity may change at short notice, for example when a start-up company rapidly “scales up”, when a new market is to be captured, or when a peak in demand (such as Christmas trade) has to be processed. There is therefore a need for storage and order picking systems which can quickly and flexibly be put into operation and can be removed and transferred to a different site within a very short period of time. 
     The object of the invention is therefore to propose a storage and order picking system for articles stored in containers, which can be installed, put into operation and dismantled again quickly and with little effort and which can also easily be adapted (scaled) to a changing throughput of goods. 
     SUMMARY OF THE INVENTION 
     According to the invention, this object is achieved by a modular storage and order picking system comprising a storage unit having a plurality of through-flow channels for receiving storage containers for storing articles, an order picking unit having one or more dispensing spaces for removing articles and one or more target spaces for collating articles relating to an order or partial order, a conveyor unit for conveying storage containers between the storage unit and the order picking unit, wherein the storage unit has a self-supporting frame structure, on which the order picking unit and the conveyor unit are mounted in a manner detachably connected to one another. 
     The modular storage and order picking system according to the invention is preferably constructed at an installation site, put into operation and tested, then is broken down into transportable modules and brought to a site of use and erected there ready for use without any further commissioning activities. A relatively long test phase can be omitted due to the test phase at the installation site, and therefore the facility is functional and ready to operate within a few hours. The modular construction of the storage and order picking system according to the invention enables the units, namely the storage unit, the order picking unit and the conveyor unit, to be transported separately and then assembled at the site of use. 
     Preferably, the storage and order picking system is not permanently connected to the floor or to a building, wherein the self-supporting frame structure stands on the floor and the through-flow channels, the order picking unit and the conveyor unit are connected thereto. 
     Preferably, the storage unit, the order picking unit and the conveyor unit are functionally connected to one another by means of detachable mechanical and electrical plug-in connections. This enables quick and safe assembly and disassembly of the facility. 
     The frame structure may be configured with dimensions corresponding to the internal dimensions of a standard container or to the maximum dimensions of a semi-trailer, thereby facilitating transportation of the facility. The storage unit may preferably be shaped as a cuboid with the self-supporting frame structure on the outside, said self-supporting frame structure being formed by suspended flat bar. 
     Preferably, the through-flow channels are arranged one above the other transversely to the longitudinal direction of the storage unit and in a manner inclined relative to the horizontal, as a result of which the containers located in the storage channels can easily be removed. The through-flow channels may be arranged in groups or stacks inclined in opposite directions. 
     Preferably, the conveyor unit has conveyor means extending on both sides along the longitudinal axis of the storage unit. This enables the containers to be stored in the through-flow channels of the storage unit and retrieved therefrom in a quick and efficient manner. The conveyor means may be held by add-on frames which can be detachably connected to the frame structure. 
     Preferably, the order picking unit is arranged on one or both end faces of the storage unit and may be configured as a manual, partially automated or fully automated order picking unit. 
     The order picking unit may have buffer spaces above or below the target spaces, said buffer spaces being served by the conveyor means. 
     Preferably, the order picking unit has an inventory management computer which records the position of the storage containers in the storage unit and enables direct access to individual storage containers. In addition, optical display means for displaying the quantity and target container of the article(s) to be picked may be provided for the order picker. 
     The conveyor means may be configured as rail-guided conveyor devices for storing the storage containers in the through-flow channels of the storage unit and retrieving them therefrom in an automated and computer-controlled manner. 
    
    
     
       DESCRIPTION OF THE FIGURES 
       The invention will be described in detail below on the basis of exemplary embodiments and with reference to the drawings, in which: 
         FIG. 1  shows a schematic perspective view of the storage unit and the frame structure of one exemplary embodiment of the modular storage and order picking system according to the invention; 
         FIG. 2  shows a schematic horizontal sectional view of one exemplary embodiment of the modular storage and order picking system according to the invention; 
         FIG. 3  shows a schematic perspective view of the storage unit of one exemplary embodiment of the modular storage and order picking system according to the invention; 
         FIG. 4  shows a schematic cross-sectional view of one exemplary embodiment of the modular storage and order picking system according to the invention; and 
         FIG. 5  shows a schematic horizontal sectional view of the order picking unit of one exemplary embodiment of the modular storage and order picking system according to the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  shows a schematic perspective view of the storage unit  10  and the frame structure  40  of one exemplary embodiment of the modular storage and order picking system  100  according to the invention. Conveyor means can be seen on both long sides. In this illustration, the order picking unit is omitted for reasons of clarity. The frame structure  40  consists of a self-supporting frame made of tubular steel, flat metal or aluminium or another suitable material and has the internal dimensions of a 40-foot container or has dimensions such that it fits on a conventional truck semi-trailer. This enables time-saving loading and unloading from both 40-foot containers and semi-trailers. 
     Integrated in the frame structure  40  is the elongate storage unit  10 , in which through-flow channels  12  for commercially available containers  14  or trays are integrated, it being possible for said through-flow channels to be arranged in groups or columns inclined in opposite directions. The containers  14  may be individually subdivided according to requirements, for example in the form of inserts. It is also possible to design the modules for different container heights. 
     Located on the long sides of the storage unit  10  and of the main frame are rail-guided, fully automatic removal devices  32  which remove containers  14  from the through-flow channels  12  and return them to storage therein (see also  FIG. 4 ). The removal devices  32  have already been put into operation and tested in a second, possibly subdivided frame  42 , which is connected to the main frame  40  via conical guide elements and electrical plug-in connections. 
       FIG. 2  shows a schematic horizontal sectional view of one exemplary embodiment of the modular storage and order picking system  100  according to the invention. The conveyor unit  30  is formed by conveyor means  32  ( FIG. 4 ) extending on both sides along the longitudinal axis of the storage unit  10 . Arranged on the end face of the storage unit  10  is the order picking unit  20 , which is attached to the short side of the main frame  40 . The storage unit  10 , the order picking unit  20  and the conveyor unit  30  form the modules of the modular storage and order picking system according to the invention. 
     The order picking unit  20  shown schematically in  FIG. 5  is functionally connected to the storage unit via the removal devices and conveyor means  32  of the conveyor unit  30 , wherein the conveyor means  32  both store the containers in the through-flow channels  12  of the storage unit  10  and also retrieve them therefrom. The order picking unit  20  preferably also contains a control cabinet, the overall control system and the inventory management computer, as well as the order picking and packing space on a platform. 
     The mode of operation of the modular storage and order picking system according to the invention will be explained below. 
     A source container  14  required for an order picking process is retrieved from the storage unit  10  according to the goods-to-person principle and is made available to the order picker at one of the dispensing spaces  22  of the order picking unit  20 . Via light indicators or a screen display (not shown), which are known per se, the order picker is directed to remove the required number and also the correct removal location (in the case of subdivided containers) and places the removed article(s) in a container at the specified retrieval space  24 . After confirmation, the container  14  is returned to the storage unit  10  by the conveyor means  32  in a fully automated manner, but not to a defined storage space but rather to a through-flow channel  12  that is selected freely or according to algorithms. Should the requested source container  14  not be at the foremost position of the through-flow channel  12 , the removal device  32  removes all the containers  14  located in front of it, one after the other and in a fully automated manner, and places them on an optional return-to-storage conveyor located in the middle of the storage unit  10 , or immediately returns said containers to storage in an opposite channel that has free spaces. If the return-to-storage conveyor is used, the opposite removal device  32  feeds said containers  14  that are not required back into the same channel or into a different free channel. 
     It is also possible for containers that will be required again in the near future, as can be seen in the order pool, to be buffer-stored in buffer spaces (not shown) above or below the target spaces  24  of the order picking module  20 . 
     The integrated inventory management system (not shown) controls and tracks all movements within the facility and controls the order picker. It therefore knows, at any given time, where each container is located and how much stock it contains. The connection to the customer&#39;s host may take place online or offline. By means of special algorithms in the inventory management system, it is possible to create specific free through-flow channels in which, upon rearrangement, containers that will be required in the near future can be stored in a targeted and chronologically optimized manner so as to shorten the access times at the time of need. 
     The modular storage and order picking system  100  according to the invention may contain further components, such as for example a separate packing table, shelves for packaging material, printers, screens, etc. 
     The modular storage and order picking system  100  according to the invention can be constructed, put into operation and used productively within a very short period of time, usually within a few hours after delivery. In contrast to conventional order picking facilities, no permanent anchoring in a building is required. The storage and order picking system  100  according to the invention consists of a self-supporting frame  40  and the add-on modules, which after delivery are merely connected to one another preferably by plug-in connections. 
     Immediately after the storage and order picking system  100  has been erected, goods can begin to be placed into storage. This takes place by taking empty containers out of storage, filling them with goods in a computer-controlled manner, and then automatically returning them to storage. As soon as sufficient goods are available (the facility need not be completely filled), the order picking mode can be started. In addition, at any subsequent point in time, the order picking mode and the refilling mode may be mixed simultaneously as required. 
     The modular storage and order picking system  100  according to the invention can be broken down, at any time and with little effort, into the individual modules and can be reassembled at a different site within a few hours. During this, the goods can remain in the storage unit  10 , as a result of which resumption of productive operation can begin immediately at the new installation site. 
     Due to the modular nature, additional facilities can be added and linked into the process without physical connection. This can be used on the one hand to achieve increases in performance or capacity, but also to cushion temporary peaks. Once the peak demand is over, modules can be removed again without any break in operation. Disassembly and transfer to a different installation site is also possible within a similarly short period of time.