Patent Description:
<CIT>, which was used by the EPO as the 'closest prior art' during the European patent examination procedure, describes a robotic cargo handling system and method. An interchange for moving shipping containers and semi-trailers between trains, between train and road vehicles and between road vehicles is described. The interchange comprises a structure located above a series or railway tracks forming part of a rail network and a series of roads forming part of a road network. The structure comprises tracks supported by the structure, the tracks forming a grid-like pattern above the transport network tracks and roads. Robotic load handlers are operable on the tracks of the grid structure and pick up containers from beneath the structure and move said containers to alternative locations, said alternative location including moving the containers between vehicles located beneath the structure. <CIT> describes a spreader system without electric cables for lifting goods containers. The spreader system comprises a spreader and two pulley sets. Each pulley of the pulley sets is fitted with a geared ring, and gears are fixed on the headblock of the spreader. An FALK-flexible coupling is fixed on a gear shaft and is connected to planetary speeder, which is, in turn, connected to a bi-directional plunger pump. Through a hydraulic circuit, the bi-directional plunger pump is connected to a hydraulic accumulating power station which comprises a hydraulic accumulator, a nitrogen bottle connected to the hydraulic accumulator through a pipeline, an oil tank, an electric generator, a battery, and an oil motor connected to the electric generator and controlled by a magnetic valve. On the spreader, there is a remote control transmitter in order to transmit signals to the remote control receiver in the cab of a container crane. While the crane hoists the spreader, due to friction, the wire rope will rotate the pulley sets, which will finally drive the bi-directional plunger pump and an accumulative power source will form.

<FIG> discloses a framework structure of a typical prior art automated storage and retrieval system <NUM> and <FIG> disclose known container-handling vehicles of such a system. The storage system is disclosed in detail in for instance NO317366 and <CIT>.

The framework structure comprises a plurality of upright members/profiles <NUM> and a plurality of horizontal members <NUM>, which are supported by the upright members <NUM>. The members <NUM>, <NUM> may typically be made of metal, e.g. extruded aluminium profiles.

The framework structure defines a storage grid <NUM> comprising multiple grid columns <NUM> arranged in rows. Most of the grid columns <NUM> are storage columns <NUM> in which storage containers <NUM>, also known as containers, are stacked one on top of another to form stacks <NUM>. Each storage container <NUM> (or container for short) may typically hold a plurality of product items that may be same or different product types depending on the application. The framework structure guards against horizontal movement of the stacks <NUM> of storage containers <NUM>, and guides vertical movement of the containers <NUM>, but does normally not otherwise support the storage containers <NUM> when stacked.

Each container-handling vehicle <NUM> comprises a lifting device <NUM> (shown in <FIG>) for vertical transportation of storage containers <NUM>, e.g. raising a storage container <NUM> from and lowering a storage container <NUM> into a storage column <NUM>. The lifting device <NUM> comprises a lifting frame <NUM>, similar to the one shown in <FIG>, which is adapted to engage a storage container <NUM>. The lifting frame <NUM> can be lowered from the vehicle body <NUM> so that the position of the lifting frame <NUM> with respect to the vehicle body <NUM> is adjusted in a third direction Z, which is orthogonal the first direction X and the second direction Y.

Each container-handling vehicle <NUM> comprises a storage compartment or space for receiving and stowing a storage container <NUM> when transporting the storage container <NUM> across the grid <NUM>. The storage space may comprise a cavity <NUM> arranged centrally within the vehicle body <NUM>, e.g. as is described in <CIT>.

Alternatively, the container-handling vehicles may have a cantilever construction, as is described in NO317366.

In a storage grid, most of the grid columns <NUM> are storage columns <NUM>, i.e. grid columns where storage containers are stored in stacks. However, a grid normally has at least one grid column <NUM> which is used not for storing storage containers, but which comprises a location where the container-handling vehicles can drop off and/or pick up storage containers so that they can be transported to an access station where the storage containers <NUM> can be accessed from outside of the grid or transferred out of or into the grid, i.e. a container handling station. Within the art, such a location is normally referred to as a "port" and the grid column in which the port is located may be referred to as a port column.

The grid <NUM> in <FIG> comprises two port columns <NUM> and <NUM>. The first port column <NUM> may for example be a dedicated drop-off port column where the container-handling vehicles <NUM> can drop off storage containers to be transported to an access or a transfer station (not shown), and the second port <NUM> column may be a dedicated pick-up port column where the container-handling vehicles <NUM> can pick up storage containers that have been transported to the grid <NUM> from an access or a transfer station.

For monitoring and controlling the automated storage and retrieval system, e.g. monitoring and controlling the location of respective storage containers within the grid <NUM>, the content of each storage container <NUM> and the movement of the container-handling vehicles <NUM> so that a desired storage container can be delivered to the desired location at the desired time without the container-handling vehicles <NUM> colliding with each other, the automated storage and retrieval system comprises a control system, which typically is computerised and comprises a database for keeping track of the storage containers.

When a storage container <NUM> stored in the grid <NUM> disclosed in <FIG> is to be accessed, one of the container-handling vehicles <NUM> is instructed to retrieve the target storage container from its position in the grid <NUM> and transport it to the drop-off port <NUM>. This operation involves moving the container-handling vehicle <NUM> to a grid location above the storage column <NUM> in which the target storage container is positioned, retrieving the storage container <NUM> from the storage column <NUM> using the container-handling vehicle's lifting device (not shown, being internally arranged in a central cavity of the vehicle, but similar to the lifting device <NUM> of the second prior art vehicle of <FIG>), and transporting the storage container to the drop-off port <NUM>. A second prior art vehicle <NUM> is shown in <FIG> to better illustrate the general design of the lifting device. Details of the second vehicle <NUM> are described in the <CIT>. The lifting devices <NUM> of both prior art vehicles <NUM> comprise a set of lifting bands <NUM> extending in a vertical direction and connected close to the corners of a lifting frame <NUM> (may also be termed a gripping device) for releasable connection to a storage container. The lifting frame <NUM> features container connecting elements <NUM> for releasably connecting to a storage container, and guiding pins <NUM> for aligning a storage container <NUM> to the lifting frame <NUM>.

To raise or lower the lifting frame <NUM> (with or without a connected storage container <NUM>), the lifting bands <NUM> are connected to a band drive assembly. In the band drive assembly, the lifting bands <NUM> are commonly spooled on/off at least two rotating lifting shafts or reels (not shown) arranged in the container-handling vehicle, wherein the lifting shafts are further connected via belts/chains to at least one common rotor shaft providing synchronized rotational movement to the at least two lifting shafts. Various designs of the lifting shafts are described in for instance <CIT> and <CIT>.

Most prior art container-handling vehicles having a central cavity for receiving a storage bin, as in <FIG>, features a lifting device <NUM> having a band drive assembly comprising at least one rotor shaft, centrally arranged in an upper section of the vehicle and connected to a lifting motor. In addition to the centrally arranged rotor shaft, such lifting devices comprise an assembly of secondary shafts and/or sheaves onto which the lifting bands are spooled on and off. The secondary shafts and/or sheaves are rotated by being connected to the centrally arranged rotor shaft via belts/chains and are arranged at the corners of the central cavity to provide the required positioning of the lifting bands <NUM> relative the lifting frame <NUM>. Having such an assembly of multiple movable parts is not an optimal solution since the lifting devices are relatively service intensive and occupies a large volume inside the robot.

A drawback with these prior art container handling vehicles are related to the lifting frame <NUM> and the gripper elements. The gripper elements receive power and signals, for when to grip and release the containers, via cables embedded in the lifting bands. This solution may present complications when the lifting bands get worn. In the current solution the lifting bands are all wound up on a rotary shaft. The constant winding and unwinding of the lifting bands on the shaft every time the lifting frame <NUM> is either raised or lowered wears on the lifting bands.

When the lifting bands get worn there is a risk of the cables providing the gripper elements with power and operating signals also gets worn and since they are rolled up on the same rotary shaft there is a risk of short circuit. A short circuit in the bands can complicate and delay the system considerably e.g. if it occurs while the container handling vehicle is digging, i.e. moving storage containers on top of a specific storage container to be accessed. If the lifting device breaks down during digging it can be a large operation getting the container handling vehicle off the storage system and getting another container handling vehicle to take over the operation of the first container handling vehicle. Also, there is a risk of damaging the container and the goods in the container. A short circuit can also lead to fire.

In view of the above it is desirable to provide a container handling vehicle with a lifting device wherein the disadvantages of the prior art are avoided.

The present invention is defined in claims <NUM> and <NUM>.

According to a first aspect of the present invention, there is provided a container-handling vehicle for picking up storage containers from a three-dimensional grid of an underlying storage system, comprising a vehicle body and at least one lifting device with a lifting frame with gripper elements for releasable connection to a storage container, and a transmitter for communicating instructions for controlling the gripper elements, where the lifting frame further comprises a first rechargeable power supply for supplying energy to the gripper elements.

Further, the container handling vehicle has at least one second rechargeable power supply configured to charging the first rechargeable power supply when the lifting frame is in its top most position, and wherein the at least one second rechargeable power supply is connected to at least one upper charger connector and the first rechargeable power supply is connected to at least one lower charger connector.

The at least one upper charger connector comprises a spring-biased contact probe, optionally wherein the at least one upper charger connector comprises a contact probe, a spring, a fixing plate, a wire connecting nut, a contact probe fixing nut, and a fixing nut and the lower charger connectors are plates of an electrically conductive material.

The at least one second rechargeable power supply and the first rechargeable power supply is a Li-ion battery and/or a capacitor.

The communication for controlling the gripper elements is wireless communication between the transmitter and a receiver situated on the lifting frame, and the wireless communication is light communication, and the light communication is implemented by one or more of Visible Light Communication (VLC), Li-Fi, Irda, Optical Wireless Communication (OWC) or Reasonable Optical Near Joint Access (RONJA).

The transmitter is a first transceiver and the receiver is a second transceiver, and the transmitter and the receiver is installed to be in line of sight of each other.

According to a second aspect of the present invention, there is provided a method for picking up storage containers from a three-dimensional grid of an underlying storage system, using a container-handling vehicle comprising a vehicle body and at least one lifting device with a lifting frame with gripper elements for releasable connection to a storage container, and a transmitter for communicating instructions for controlling the gripper elements, wherein the method comprises the following steps lowering the lifting frame, communicating instructions to the lifting frame by means of the transmitter transmitting a signal to actuate the gripper elements, using a first rechargeable power supply, situated on the lifting frame, for supplying energy to actuate the gripper elements, lifting the lifting frame,
using a power reading device to read the charge level of the first rechargeable power supply, using a second rechargeable power supply to charge the first rechargeable power supply if the first rechargeable power supply has a charge level below a set threshold level.

Further the method comprises using a first transceiver to communicate instructions to the lifting frame by means of transmitting light signals to a second transceiver to activate the gripper elements.

So, the present invention provides a solution where neither signals nor power is transferred directly from the container handling vehicle to the gripper elements on the horizontal lifting frame via electrical leads when the lifting frame is operating within the storage grid.

Certain embodiments will now be described in greater detail by way of example only and with reference to the accompanying drawings, in which:.

<FIG> is a perspective view of an exemplary storage system. Here it is disclosed a framework structure of a typical prior art automated storage and retrieval system <NUM>. The framework structure comprises a plurality of upright members/profiles <NUM> and a plurality of horizontal members <NUM>, which are supported by the upright members <NUM>. The members <NUM>, <NUM> may typically be made of metal, e.g. extruded aluminium profiles.

The framework structure defines a storage grid <NUM> comprising multiple grid columns <NUM> arranged in rows. Most of the grid columns <NUM> are storage columns <NUM> in which storage containers <NUM>, also known as containers, are stacked one on top of another to form stacks <NUM>. Each storage container <NUM> (or container for short) may typically hold a plurality of product items (not shown), and the product items within a storage container <NUM> may be identical or may be of different product types depending on the application. The framework structure guards against horizontal movement of the stacks <NUM> of storage containers <NUM>, and guides vertical movement of the containers <NUM>, but does normally not otherwise support the storage containers <NUM> when stacked.

<FIG> is a perspective view of a prior art container handling vehicle with a central cavity for storing containers. In this solution the lifting device and the lifting frame <NUM> with the gripper elements is stored inside the central cavity when it is raised. The benefit of such a solution is that the container handling vehicle takes up less space of the underlying grid allowing for more container handling vehicles to operate at the same time.

<FIG> is a side view of a prior art container handling vehicle wherein the lifting frame <NUM> is displayed, first in a raised position and second in a slightly lowered position. The container handling vehicle presented here is a cantilever solution wherein the lifting device and the lifting frame <NUM> with the gripper elements are placed adjacent to the main body of the container handling vehicle. A benefit with this solution is that the container is placed away from the main power source and the electro motors running the container handling vehicles.

<FIG> is a side view of a container handling vehicle according to an embodiment of the present invention wherein the lifting frame <NUM> is displayed. Although the container handling vehicle displayed here is a cantilever solution the present invention can just as well be used on a container handling vehicle with a central cavity for storing containers.

The container handling vehicle comprises a main body and a cantilever extension. In the main body there is a second rechargeable power supply <NUM>. This second rechargeable power supply <NUM> can preferably be a Li-ion battery or a capacitor. The second rechargeable power supply <NUM> delivers power to at least one electrically powered motor. The electrically powered motor maneuvers the container handling vehicle on the grid of the underlying storage system. The electrically powered motors provide motion to at least two sets of wheels. Further the main body can have a central control center.

In the embodiment presented in <FIG> there is a cantilever extension on the main body where the lifting device is situated. In an alternative embodiment the lifting device can be situated inside the body of a central cavity container handling vehicle. This makes no difference to the solution of the present invention.

The lifting device comprises a lifting band drive assembly connected to the vehicle body. To the lifting band drive assembly there is attached at least one rotatable lifting shaft. To the rotatable lifting shaft there is attached a plurality of lifting bands <NUM>. To the lifting bands <NUM> there is attached a horizontal lifting frame <NUM>. On this lifting frame <NUM> there is at least one set of gripping elements for releasable connection to a storage container.

To the bottom part of the cantilever extension there is attached at least one upper charger connector <NUM>. The upper charger connector <NUM> is connected to the second rechargeable power supply <NUM>. The second rechargeable power supply <NUM> can charge a first rechargeable power supply <NUM> situated on the horizontal lifting frame <NUM>. The charging of the first rechargeable power supply <NUM> is done when the lifting frame <NUM> is at its upper most position.

The second rechargeable power supply <NUM> is the main power supply for the container handling vehicle. The power is used for manoeuvring the container handling vehicle and to give power to the lifting of the containers by the horizontal lifting frame <NUM>. Further the second rechargeable power supply <NUM> is used to power the central controller system, which is the main computer system of the container handling vehicle, and to charge the second rechargeable power supply.

The first rechargeable power supply <NUM> is used to power the gripper elements <NUM> on the horizontal lifting frame <NUM>. The first rechargeable power supply <NUM> is also situated on the horizontal lifting frame <NUM>.

The at least one upper charge connector is connected to the second rechargeable power supply <NUM>. The at least one upper charger connector <NUM> are touching at least one lower charger connector <NUM> when the horizontal lifting frame <NUM> is at its top most position. The at least one lower charger connector <NUM> is attached to the upper side of the horizontal lifting frame <NUM>. From here it is connected to the first rechargeable power supply <NUM>.

A power reading device <NUM> can check if the first rechargeable power supply <NUM> needs to be charged when the horizontal lifting frame <NUM> is at its top most position. If the first rechargeable power supply <NUM> needs to be recharged the power is transferred from the second rechargeable power supply <NUM> to the first rechargeable power supply <NUM> via the upper and the lower charger connectors <NUM>. If the power reading device concludes that the first rechargeable power supply <NUM> do not need to be charged, no power is transferred from the second rechargeable power supply <NUM> to the first rechargeable power supply <NUM> via the upper and the lower charger connectors <NUM>.

The first rechargeable power supply <NUM> can be a Li-ion battery or a capacitor.

The when the horizontal lifting frame <NUM> is lowered into the underlying grid of the storage system, vertical guide pins <NUM> ensures that the lifting frame <NUM> is lowered correctly into the shaft and connects properly with the container. There is a vertical guide pin in each corner of the horizontal lifting frame <NUM>.

When the lifting frame <NUM> has connected properly to the container the central controller system tells the gripper elements <NUM> to grip the container. The central controller system communicates the information to a transmitter <NUM> using light as a medium for communication. The transmitter <NUM> is situated in a lower part of the cantilever extension. The transmitter <NUM> transmits information directly downwards to a receiver <NUM> situated on an upper surface of the horizontal lifting frame <NUM>. From here the information received by the receiver is transmitted along a wire to the gripper elements <NUM> and the gripper elements <NUM> either grips a container or releases a container depending on the information sent by the central controller system.

The gripper element <NUM> is connected to a gripper sensor <NUM>. The gripper sensor <NUM> gives information regarding if the gripper elements <NUM> are actually gripping a container. The sensor can give this information in the form of feedback to the central controller system. Further, the gripper sensor <NUM> can also measure the amount of force the gripper elements <NUM> are using.

Further the transmitter <NUM> can be a first transceiver and the receiver <NUM> can be a second transceiver ensuring a two-way communication between the lifting frame <NUM> and the central control system.

The light communication can be implemented by one or more of Visible Light Communication (VLC), Li-Fi, Irda, Optical Wireless Communication (OWC) or Reasonable Optical Near Joint Access (RONJA).

Further the transmitter <NUM> and the receiver <NUM> must be in line of sight of each other.

<FIG> is a side view of the charging circuit of how the second rechargeable power supply <NUM> can charge the first rechargeable power supply <NUM> according to a preferred embodiment of the present invention.

The second rechargeable power supply <NUM> is connected to two upper charger connectors <NUM>. The contact probe <NUM> of the upper charger connectors <NUM> protrudes from the bottom surface of the cantilever extension. In a central cavity solution, the contact probe <NUM> of the upper charger connector <NUM> will protrude slightly from a lower part of the cantilever extension of the container handling vehicle.

When the lifting frame <NUM> is in its top most position, the two upper charger connectors <NUM> are in physical contact with a corresponding pair of lower charger connectors <NUM>. These lower charger connectors <NUM> according to a preferred embodiment of the present invention is in the form of plates of an electrically conductive material. The lower charger connectors <NUM> are mounted to the top side of the lifting frame <NUM>. The lower and the upper charger connectors <NUM> are adjacent to each other so that they will touch when the lifting frame <NUM> is in its top most position.

A power reading device <NUM> can read of the charge level of the first rechargeable power supply <NUM> when the upper and the lower charger connectors <NUM> are in physical contact with each other. If the first rechargeable power supply <NUM> need to be recharged the second rechargeable power supply <NUM> will charge the second rechargeable power supply. If the first rechargeable power supply <NUM> has sufficient charge no power is transferred from the second rechargeable power supply <NUM> to the first rechargeable power supply <NUM>.

Claim 1:
A container-handling vehicle (<NUM>) for picking up storage containers (<NUM>) from a three-dimensional grid (<NUM>) of an underlying storage system (<NUM>), comprising a vehicle body (<NUM>) and at least one lifting device (<NUM>) with a horizontal lifting frame (<NUM>) with gripper elements (<NUM>) for releasable connection to a storage container (<NUM>), characterized in that:
the container-handling vehicle (<NUM>) further comprises a transmitter (<NUM>) for communicating instructions for controlling the gripper elements (<NUM>), the horizontal lifting frame (<NUM>) further comprises a first rechargeable power supply (<NUM>) for supplying energy to the gripper elements (<NUM>), and the container handling vehicle (<NUM>) has at least one second rechargeable power supply (<NUM>) configured to charge the first rechargeable power supply (<NUM>) when the horizontal lifting frame (<NUM>) is in its top most position, and the at least one second rechargeable power supply (<NUM>) is connected to at least one upper charger connector (<NUM>) and the first rechargeable power supply (<NUM>) is connected to at least one lower charger connector (<NUM>), and the at least one lower charger connector (<NUM>) is attached to the upper side of the horizontal lifting frame (<NUM>) and from here it is connected to the first rechargeable power supply (<NUM>), wherein the at least one upper charger connector (<NUM>) is touching the at least one lower charger connector (<NUM>) when the horizontal lifting frame (<NUM>) is at its top most position, and wherein the at least one upper charger connector (<NUM>) comprises a spring-biased contact probe (<NUM>), a spring (<NUM>), a fixing plate (<NUM>), a wire connecting nut (<NUM>), a contact probe fixing nut (<NUM>), and a fixing nut (<NUM>).