Patent Publication Number: US-2021188572-A1

Title: System for moving goods into, out of, and within high-bay storage

Description:
The invention relates to a transport and transfer system for storing and retrieving or relocating storage items in a high-bay warehouse, particularly in a transshipment facility of a seaport or an inland port for storage of standard containers where the high-bay warehouse has a plurality of storage modules that are in rows in longitudinal direction and in width direction transversely thereto of the high-bay warehouse and in height have a plurality of rack bays disposed one above the other and that are separated from one another by lanes extending parallel to the storing and retrieving sides of the rack bays or of the storage modules, wherein at least one storage and retrieval apparatus that is movable back and forth, for transporting as well as storing and retrieving or relocating the storage items is in each lane. 
     An integrated, fully automatic container transport system of the kind stated in the introduction with storage and retrieval apparatus arranged in each lane is known from WO 2015/124342 A1 for a transshipment facility of a seaport or an inland port. 
     The storage and retrieval apparatus that in its dimensions is of narrow construction and that stores and retrieves the containers with the longitudinal sides thereof foremost in the rack bays, is movable in floor-bound manner in longitudinal direction of the lanes. The raising and lowering of the hoist platform that is provided with load receiving means, of the storage and retrieval apparatus is carried out by a cable traction device or a hoist, comprising a cable, cable drums, deflecting rollers, motors and transmissions. Provided at the hoist platform for suspended transport of the containers are load receiving means that are constructed in particularly space-saving manner as telescopic forks or tables for gradual horizontal movement in and out together with a suspended container. 
     For transfer of the containers transported to the delivery side—this is usually the side of the high-bay warehouse facing the vessel—and to be transported away at the other end of the warehouse it is necessary to provide in front of and behind each lane appropriate preparation stations from which the storage and retrieval apparatus takes over the containers for storage or in which the containers can be deposited for retrieval. That is equally so in the case of in a high-bay warehouse for storage and retrieval of, for example, strips wound to form bundles (coils), particularly rolled metal strips, wherein the coils are taken over from shelves and deposited on shelves or substructures in the rack bays. 
     In the case of a container terminal known from DE 44 9 740 Cl high transshipment rates, such as have to be guaranteed by, for example, use of several loading or container bridges at a vessel are achieved by a fully automated container transport system that is integrated in a container transshipment facility, in conjunction with loading cranes. For that purpose, track levels that are connected together by a plurality of supports and are offset in height, with loading and unloading positions are on a step-shaped support construction offset in height, wherein each level has a track network with a plurality of transport pallets operated by linear motor and movable thereon. Apart from the fact that a large number of transport pallets specially constructed with linear motor drives as contactless drive means is needed, a substantial outlay on steel construction is unavoidable with the track network, because each level has several interconnected tracks for movement of the transport pallets on a track network to loading and/or unloading and/or junction positions. The different or individual levels interconnected by supports are predetermined by a step-shaped support construction offset in height. 
     A very large outlay, as described above, additionally with substantial steel structures is also required in a high-bay warehouse with elevated rail tracks when the transfer stations on the uppermost storeys of the high-bay warehouse are integrated into the steel structure and storage cranes that are compartmented by roof attachments and that extend over the lanes to serve all successive multistory storage modules, take over distribution of the supplied containers to the storage and retrieval apparatus. 
     The invention has the object of creating a transport and transfer system according to category, which enables further accelerated transshipment of storage items such as flat containers, coils and, in particular, standard containers (20 TEU and 40 FEU containers) or otherwise for take-over, by suspension, of suitable storage items, with reduced outlay and fewer steel structures. 
     According to the invention this object is fulfilled in that the high-bay warehouse is constructed with at least one transverse conveyor that crosses at least some lanes and that conveys the supplied storage items into and/or out of the high-bay warehouse. 
     Starting from the assumption that the lanes run parallel to the long sides, i.e. the longitudinal sides of the high-bay warehouse, the transverse conveyor extends or several transverse conveyors—that can be provided in distribution at a spacing from one another at the longitudinal sides—extend over the entire width of the high-bay warehouse and advantageously end outside the high-bay warehouse near the longitudinal sides thereof. The transverse conveyor can consist of, for example, roller-path rollers of which at least some are driven and on which standard containers deposited in pallets, containers directly deposited thereon or coils deposited on shelves run out and can be positioned for further handling. The storage items that have been conveyed in can then be taken over by the storage and retrieval apparatus and stored in the rack bays or, by reverse movement sequences, retrieved. The sequence of storage and retrieval can be substantially shortened in time because the storage and retrieval apparatus no longer has to cover large travel paths, since the transverse conveyors crossing either all lanes or—in the case of a divided construction of the transverse conveyor—at least some, for example two or three, lanes take over provision or distribution—that is selective in the high-bay warehouse—of the taken-over storage items supplied from outside the high-bay warehouse and the conveying in and out thereof. The transverse conveyor according to the invention, which optionally can be provided from a plurality of sections horizontally offset relative to one another and crossing the high-bay warehouse, makes it possible in every case for storage items supplied below the travel plane or travel rail plane of the storage and retrieval apparatus to be handled in variable manner in the high-bay warehouse during both storage and retrieval. 
     A preferred embodiment of the invention provides that the transverse conveyor is constructed in a pit of the warehouse foundation. The underpasses for the transverse conveyors can be provided in simple manner directly at the time of the foundation work, which facilitates production. 
     If a return path for return transport of empty pallets, conveying carriages or substructures is advantageously below the transverse conveyor in the pit of the warehouse foundation, in which case the return path combined with the transverse conveyor can similarly have, for example, roller-path rollers or like conveyors, it is possible to achieve closed-circuit use of the means receiving the storage items. 
     According to another, slightly modified embodiment of the invention the transverse conveyor can be constructed on the warehouse foundation of the lowermost rack bay level of at least one row of successive storage modules. In this case, the transverse conveyor is constructed on the existing foundation of the lowermost rack bays, which makes retrofitting of an existing high-bay warehouse with a transverse conveyor possible in simple manner. The storage items are in that case conveyed in and out from the longitudinal side of the high-bay warehouse. In order to utilize full storage capacity, after occupation of all other rack bays the rack bays of the lowermost rack bay level can still be used. 
     In addition, in this variant according to an advantageous proposal of the invention a return path for return transport of empty pallets, carrier shelves or conveying carriages in closed circuit is below the transverse conveyor in the warehouse foundation. 
     The return path can optionally extend parallel to the transverse conveyor, i.e. on the warehouse foundation of the adjacent lowermost rack bay level or on the floor of the pit of the foundation. Whereas in the case of a return path that is deeper by comparison with the transverse conveyor the transport flow takes place in two height levels—in which case the height difference for raising or lowering the storage items or the pallets, conveying carriages or the like can be overcome by, for example, lifting tables—in the case of an arrangement that runs in parallel adjacent manner in one height level, of the transverse conveyor and return path the transfer of empty pallets, conveying carriages or the like to the return path can be taken over by linear displacing means, for example cylinders. 
     It is proposed to make use of, for preference, storage and retrieval apparatus that comprises a frame that consists of vertical posts and head crossbars and foot beams interconnecting these and that corresponds with the height of the multistory storage modules, with a hoist platform that is moved at the vertical posts by drive means and that is constructed for servicing of the rack bays of the adjacent storage modules on the left-hand side and right-hand side by load receiving means insertable and withdrawable orthogonally to the lane, as known per se, wherein accordance with the invention the foot beam is of frame-like construction with a passage opening for the storage items to be lifted through. The passage opening that is matched to the largest occurring dimension of the storage items, enables free passage of the storage items during lifting from or lowering onto the transverse conveyor arranged in the foundation pit. The same applies in the case of use of the lowermost rack bay level for the transverse conveyor. According to the invention, in that case the storage and retrieval apparatus is movable on two rails arranged in the lanes at a horizontal spacing from and parallel to one another above the lowermost rack bay level, i.e. in the transition from the lowermost rack bay level to the rack bay level following thereabove. Such storage and retrieval apparatus having in the foot beam a passage opening for lifting through the storage items in addition enables handling of storage items in the lanes below the level of the travel rails. 
     Handling of the storage items below the travel plane of the storage retrieval apparatus is advantageously facilitated if the vertical posts of the frames are extended downwardly beyond the foot beam and protrude somewhat into the lowermost rack bay level. This thus offers a possibility for centered guidance of the lowering or rising hoist platform of the storage and retrieval apparatus by this downwardly prolonged path, for example by rollers supported on the frame extensions. 
    
    
     
       Further features and details of the invention are evident from the claims and the following description of embodiments of the invention schematically illustrated in the drawings for the transshipment of standard containers, wherein: 
         FIG. 1  is a partial cross-sectional view of a container transshipment facility and a transfer station upstream of a high-bay warehouse, for taking containers from a vessel (not illustrated) and conveying them to in front of the high-bay warehouse for storage by a storage and retrieval apparatus movable in the lanes thereof on elevated rails therein or for transport away in the case of retrieval with then reverse movement sequences, the high-bay warehouse having in linear alignment with the transfer station a transverse conveyor constructed in the lowermost rack bay level and a return path recessed or disposed deeper in the warehouse foundation; 
         FIG. 2  is a cross-sectional detail view of a container transshipment facility in a high-bay warehouse where, unlike  FIG. 1 , the unillustrated transfer stations are upstream of the openings of the lanes and the transverse conveyors and the return paths are in pits of the warehouse foundation and (not illustrated) outside the high-bay warehouse near the longitudinal sides thereof; 
         FIG. 3  is a partial longitudinal view of a detail of  FIG. 2  and of a lane with storage and retrieval apparatus movable therein on the foundation; 
         FIG. 4  is an overall view of the storage and retrieval apparatus as seen from the longitudinal side facing the storage modules or rack bays; 
         FIG. 5  is a detail view of the storage and retrieval apparatus of  FIG. 4  substantially showing the foot beam or travel frame with the hoist platform lowered together with a suspended container to above a lowermost rack bay level or a transverse conveyor arranged in a pit of the foundation (cf.  FIG. 2 ); and 
         FIG. 6  is a plan view of  FIG. 5 . 
     
    
    
     At least one transfer station  4  for unloading containers  1  from a vessel and storage in a high-bay warehouse  2  or, conversely, retrieval and loading of a vessel or a vehicle for onward transportation is, according to  FIG. 1 , in front of the high-bay warehouse  2  at the side facing the quay  3 . This comprises in linear succession in feed direction (arrow)  5  on the quay from outside towards the high-bay warehouse  2  a take-over carriage  6 , a distributor vehicle  7  movable out of the line parallel to the high-bay warehouse  2 , a stationary deposit  8  and a lifting table  9 . The transfer station  4  adjoins, in a line, a transverse conveyor  13  crossing all of the lanes  11  running in the high-bay warehouse  2  between storage modules  10  that follow one another at a mutual spacing over the width, with rack bays  12  therein over the entire height and parallel to the longitudinal sides of the high-bay warehouse. The transverse conveyor  13  is in the lowermost rack bay level  14  on the warehouse foundation  15 . A return path  16  is constructed in the warehouse foundation  15  below the transverse conveyor. 
     The transfer station  4  is in a two-level construction, i.e. the take-over carriage  6 , the distributor vehicle  7 , the stationary deposit  8  and the lifting table  9  have an upper level  1  and a lower level  11 , wherein the lifting table  9  serves the purpose of overcoming height differences between, on the one hand, the upper level  1  of the transfer station  4  as well as the transverse conveyor  13  and, on the other hand, the lower level  11  as well as the return path  16 , and of guaranteeing the respective linear path. This is because the container  1  lifted off a vessel by load receiving means  17  of a loading bridge (not illustrated) —optionally two containers  1  can be directly lifted off simultaneously by the load receiving means  17  and delivered to the take-over carriage  6 —is deposited, with its longitudinal side facing in feed direction  5 , on the upper level  1  of the take-over carriage  6  on a pallet  18  provided thereat, transferred to the uppermost level  1  of the distributor vehicle  7  and transported through movement of the distributor vehicle  7  parallel to the high-bay warehouse  2  until in front of a free stationary deposit  8  of one of the plurality of transfer stations  4  and conveyed from this to the uppermost level  1  of the lifting table  9 . 
     The lifting table  9  lowers the pallet  18  together with the container  1  until in a position aligned with the transverse conveyor  13  that then positions the previously taken-over pallet  18  together with the container  1  in one of the lanes  11  for take-over by storage and retrieval apparatus  19  arranged in each lane  11 . The pallets  18  free after taking over of the containers  1  by the storage and retrieval apparatus  19  are lowered at the end of the transverse conveyor  13  by lifting means onto the return path  16  that is recessed in the warehouse foundation  15  and is deeper and that similarly can have, for example, roller-path rollers or the like, and transported oppositely to the feed direction  5  until initially on the lifting table  9  that is adjusted with its lower level  11  in alignment with the return path  13 , of the transfer station  4 . The lifting table  9  is thereafter raised until its lower level  11  is in alignment with the lower levels  11  of the stationary deposit  8 , the distributor vehicle  7  and the take-over carriage  6 , so that the pallets  18  are returned by the conveying means of the aforesaid transfer station units to their starting position for reuse. For that purpose, the take-over carriage  6  is similarly equipped with lifting means that lift the pallets  18  from the lower level  11  to the upper level  1 . 
     The storage and retrieval apparatus  19  looks after storage and retrieval or rearranging of the containers  1  into or from the rack bays  12  of the storage modules  10  and, in the embodiment according to  FIG. 1 , is movable on two rails  20  arranged at a horizontal spacing from one another in the lanes  11  between the lowermost (first) rack bay level  14  and the (second) rack bay level following above that. For storing, a container  1  positioned in a lane  11  is lifted off its pallet  18 , for which purpose a hoist platform  21  (cf.  FIG. 4 )—that as known from WO 2015/123342 A1 can comprise at least two gradual telescopic load receiving means  22 , wherein these for adaptation to different lengths of the containers  1  can be movable towards one another or away from one another—is lowered until the telescopic load receiving means  22  arrives above the suspension points of the container  1  by its locking means for locking. The locked and suspended container  1  can thereafter be brought, by raising the hoist platform  21  and moving the storage and retrieval apparatus  19 , in front of any rack bay  12  of the adjacent storage modules  10  and be stored in the desired rack bay  12  by gradual telescoping of the load receiving means  22  (telescopic forks or telescopic table). Retrieval takes place with reversed movement sequences. 
     The free passage of the containers  1  that are taken over from the lowermost rack bay level  14 , during storage in the rack bay levels following thereabove, as illustrated in  FIG. 6 , is made possible by a frame-like construction of the foot beam  23  of the storage and retrieval apparatus  19  with a passage opening  24 . 
     The storage and retrieval apparatus  19  enabling space-saving lanes  11  that are very narrow due to the telescopic load receiving means  22  and that correspond with the width dimension of the containers, has—as apparent particularly from  FIG. 4  showing the hoist platform  21  with a suspended container  1  in the uppermost position and in a downwardly lowered position (cf.  FIG. 5 )—a frame  27  that consists of vertical posts  25  and a head crossbar  26  interconnecting these as well as the connecting foot beam  23  constructed with the passage opening  24  for the containers  1  or storage items and that corresponds with the height of the multistory storage modules  10 . The raising and lowering of the hoist platform  21  is carried out by hoists  28  at the foot beam  23  and cables  29  deflected at the head crossbar  26  by rollers. In the case of use in, in particular, a construction of the transverse conveyor  13  according to  FIG. 1 , the vertical posts  25  are provided with an extension  30  projecting over a short travel path downwardly beyond the foot beam  23  (cf.  FIG. 4 ). 
     In the transshipment facility of  FIGS. 2 and 3 , the transverse conveyors  113  and the return paths  116  combined therewith and deeper are provided so as to be completely recessed in pits  31  that cross under the high-bay warehouse  2 , of the warehouse foundation. The storage and retrieval apparatus  19  can thus be at ground level, i.e. be moved directly on the warehouse foundation  15  (cf.  FIG. 3 ). The above-described transfer stations  4  are here at the quay side in a position aligned with the lanes  11 . The containers  1  fed by the load receiving means  17  of the loading bridges from the vessel are again deposited on take-over carriages  6  in pallets  18 , transferred to the distributor vehicle  7  and transferred from this to the stationary deposits  8 . If the containers  1  are fed by the load receiving means  17  of the loading bridges so as to face not by the narrow ends thereof, but by the wide sides thereof in the direction of the lanes, a rotary table orienting the containers  1  can be upstream of the stationary deposits  8  in the transfer station. The containers  1  positioned in this way in front of the lanes are taken over from there by the storage and retrieval apparatus  19  for storage in the rack bays  12  of the storage modules  10  and the empty pallets  19  are lowered by the lifting table  9  for return to the lower level  11 . 
     The retrieval of the containers  1  after lowering thereof through the passage opening  24  of the foot beam  23  of the storage and retrieval apparatus  19  into the pit  31  is carried out by the transverse conveyor  113  and the return transport of the empty pallets  18  by the return path  116 , wherein the transverse conveyors  113  and the return paths  116  end outside the high-bay warehouse  1  near the longitudinal-side outer walls thereof and lifting tables for the containers  1  and on the other hand the empty pallets  18  are there. The lifted containers  1  can be taken over by cranes for loading of, for example, a truck or a vessel. The lowered empty pallets  18  are transported by the return path  116  or the conveying means thereof for lifting to the higher level of the transverse conveyor  113  and positioned by these for reloading with a container  1  that is to be retrieved, below a lane. 
     
       
         
           
               
             
               
                   
               
               
                 Reference numeral list 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
            
               
                 1 
                 container/storage items 
               
               
                 2 
                 high-bay warehouse 
               
               
                 3 
                 quay 
               
               
                 4 
                 transfer station 
               
               
                 5 
                 feed direction (arrow) 
               
               
                 6 
                 take-over carriage 
               
               
                 7 
                 distributor vehicle 
               
               
                 8 
                 stationary deposit 
               
               
                 9 
                 lifting table 
               
               
                 10 
                 storage module 
               
               
                 11 
                 lane 
               
               
                 12 
                 rack bay 
               
               
                 13; 113 
                 transverse conveyor 
               
               
                 14 
                 lowermost rack bay level 
               
               
                 15 
                 warehouse foundation 
               
               
                 16; 116 
                 return path 
               
               
                 17 
                 load receiving means (of the loading bridge) 
               
               
                 18 
                 pallet 
               
               
                 19 
                 storage and retrieval apparatus 
               
               
                 20 
                 rails of the storage and retrieval apparatus 
               
               
                 21 
                 hoist platform 
               
               
                 22 
                 load receiving means 
               
               
                 23 
                 foot beam/travel frame 
               
               
                 24 
                 passage opening 
               
               
                 25 
                 vertical posts 
               
               
                 26 
                 head crossbar 
               
               
                 27 
                 frame 
               
               
                 28 
                 hoist 
               
               
                 29 
                 cable 
               
               
                 30 
                 extension (of the vertical posts) 
               
               
                 31 
                 pit 
               
               
                 l 
                 upper level 
               
               
                 ll 
                 lower level