Patent Description:
Operations for storing goods, transporting them and retrieving them with the required content from the storage area, collecting them and preparing them for further processing. Bundling processes are the most time consuming and costly part of the e-commerce supply chain, which involves a large proportion of manual labor.

During the operation of the system, there is a need for storing boxes with goods, their delivery to a person - a buyer, a person - an operator or an automatic device in a certain sequence. So as to allow the buyer, operator or device to sequentially assemble the boxes necessary to complete the task. To carry out these processes, human-controlled technology is used, and manual labor is also used, which leads to a decrease in the storage density of goods in the storage system. As a result, an increase in its size is desirable for the system to function without manual labor in order to reduce operational costs and errors.

Known overhead robotic system for moving stacked objects, are described in published international application <CIT>. The system includes a portal unit configured to move over objects located in the warehouse area. Also, a gripper is provided attached to the portal block and movable along the portal block. From <CIT>a storage system is known which comprises at least two tiers arranged on top of each other, which each comprises a plurality of storage places arranged in rows in two horizontal directions perpendicular to each other, a plurality of boxes accommodated individually in these storage places and at least two, preferably all, tiers comprise the storage places; wherein a first transport network with a plurality of first rail tracks horizontally arranged within each tier is provided, wherein the first rail tracks are adapted to accommodate mobile transporting devices for their transportation; wherein each of the plurality of mobile transporting devices is adapted to accommodate at least one box from a storage place and move the accommodated box along the respective first rail tracks towards, away and/or between the storage places of the tier; and wherein at least partially above the first tier an assembly area is provided; wherein the assembly area comprises a second transport network, with a plurality of second rail tracks oriented horizontally and parallel to each other, adapted to accommodate mobile actuating devices along them for their transportation, wherein each of the plurality of mobile actuating devices is provided with a gripper adapted to grab and transfer at least some content of a box within the first tier, while such box and one of the mobile actuating devices are arranged above each other. Via laterally accessible rail tracks boxes can be moved between the storage space and a loading pedestal. Separate access to individual boxes within the storage space is not possible.

The main disadvantage of this system is its low efficiency due to the presence of only one capture.

There is a known item handling system described in the application <CIT>, containing two perpendicular sets of rails forming a grid over a plurality of stacks of containers. The system also contains many of the first robotic loading devices for net-work over stacks of containers.

Each load loading device includes a housing mounted on wheels. A housing having a lifting means for lifting a container from a stack of containers. A first set of wheels configured to engage rails of a first set of rails. And a second set of wheels configured to engage the rails of the second set of rails. The first set of wheels is independently movable and steerable with respect to the second set of wheels. So, when moving, only one set of wheels will come into contact with the net at any given time, thereby allowing the devices to move the load along the rails, controlling only the set of wheels meshed with the rails, in which some of the stacks are configured to include containers with a larger cross-sectional area than the containers in the rest of the stacks.

In addition, the system comprises at least one second robotic cargo handling device for working on a mesh. and is configured to lift and move containers from within portions of stacks configured to include large containers.

The disadvantages of this system are the complexity of the robotic devices included in it and the impossibility of collecting the kits.

The technical object of the present invention is to expand the arsenal of technical means of automatic systems for storing materials and collecting sets from them by completely eliminating manual labor.

In addition, the technical result is also an increase in the productivity of the automatic system due to multi-threaded processing of boxes with materials and completing the set.

The following is a summary of the invention. Thus, it may contain simplifications, generalizations, inclusion and / or exclusion of details. Therefore, those skilled in the art should appreciate that this summary is illustrative only and is not intended to be limiting in any way.

According to the invention the technical task is solved by a system according to claim <NUM> which is a system for storing and organizing materials comprising:
at least two tiers arranged on top of each other comprising a first tier and at least one further tier that is arranged below the first tier, each of which comprises a plurality of storage places arranged in rows in two horizontal directions, perpendicular to each other, and serving to accommodate boxes; a plurality of boxes accommodated individually in these storage places and at least two preferably all, tiers comprise the storage places, wherein a first transport network with a plurality of first rail tracks crosswise connected and horizontally arranged within each tier is provided, the first rail tracks are adapted to accommodate mobile transporting devices for their transportation; wherein each of the plurality of mobile transporting devices is adapted to pick up and accommodate at least one box from a storage place and move the accommodated box along the respective first rail tracks towards, away and/or between the storage places of the tier, wherein the first transport network of each tier is also provided below the position of a storage place and wherein mobile transport devices by themselves are adapted to pass through below a stored box in a storage place on the first transport network from one side of the storage place to the opposite side; wherein at least partially above the first tier an assembly area is provided; wherein the assembly area comprises a second transport network, with a plurality of second rail tracks oriented horizontally and parallel to each other, adapted to accommodate mobile actuating devices along them for their transportation; wherein each of the plurality of mobile actuating devices is provided with a gripper adapted to grab and transfer at least some content of a box within the first and/or any further tier arranged below the first tier, while such box and one of the mobile actuating devices are arranged above each other.

A tier can be recognized as a (first) layer of box storage space of which several can be placed on top of each other (horizontally).

A storage place can be seen as an individual storage area for one or a group of storage units, in particular a box. An individually stored box can also be a group of boxes defining a subgroup of the total number of storable boxes.

The second transport network is preferably located on top of the tier which is located the highest of all arranged tiers. The second transport network is preferably provided as a top layer of the system.

The first rail tracks are part of each provided tier, are arranged within below or above each provided tier. In one embodiment several tiers may share the first rail tracks as an individual layer of the first rail tracks or a sum of layers of the first rail tracks.

According to the present invention a mobile transporting device is provided preferably for transportation purposes of boxes towards, away of between storage spaces. Preferably the mobile transporting device is moved along the first rail tracks.

According to the present invention mobile actuating devices are located on the second rail tracks and/or are provided for transportation of goods from, between or into boxes.

According to the invention there is at least one further tier that is arranged below the first tier. So, there can be at least two tiers, thus two layers of storage places within the system (or <NUM>, <NUM>, <NUM> ,<NUM>, <NUM>, <NUM>, <NUM>, <NUM>,.

According to the invention, a first transport network with a plurality of first rail tracks crosswise connected and horizontally arranged within each tier is provided. Thus, the first rail tracks can comprise tracks that are perpendicular and connected to each other.

According to a preferred embodiment of the invention, tiers that are arranged on top of each other are connected by a delivery system that grants mobile transporting devices (located on one tier) access to another tier. This feature can be provided e.g., as an elevator or a slope connecting the individual tiers. Preferably, the delivery system is located adjacent to the stacked tiers and connected to the same.

According to a preferred embodiment of the invention, the delivery system is provided in form of a ramp that connects the first rail tracks of one tier with the first rail tracks of at least one other tier, preferably all other tiers.

According to a preferred embodiment of the invention, the first and second rail track(s) have at least one point of vertical intersection that gives a direct view from the first track to a second track below, allowing for transport and/or deployment of goods by a mobile actuating device to a mobile transporting device of the first tier, preferably also of any tier below the first tier.

According to a preferred embodiment of the invention, the movement of mobile actuating devices and/or mobile transporting devices is fully automated.

According to a preferred embodiment of the invention, a terminal is provided that inputs and outputs boxes from and to the system.

For a better understanding of the essence of the proposed technical solution, below is a description of a specific example of execution, which is not a limiting example of the practical implementation of an automatic system for storing materials and collecting sets of them. In accordance with the claimed invention with reference to the drawings, which show the following.

It should be appreciated that only those details are shown in the drawings that are necessary to understand the essence of the proposal. Related equipment well known to those skilled in the art are not shown in the drawings.

As shown in <FIG>, an automatic system for storing materials and collecting sets from them may comprise a control module <NUM> and/or a multi-level system <NUM>. The control module <NUM> may comprise a central control processor <NUM> and/or an order processing unit <NUM> and/or interface <NUM> and/or a wireless interface <NUM>.

The layered system <NUM> may comprise rack units <NUM> (storage places) and/or a first transport network <NUM> (first rail tracks) and/or a (group of) ramp(s) <NUM> and/or a second transport network <NUM> and/or a terminal <NUM> and/or transport mobile devices <NUM> (TMU) and/or executive mobile devices <NUM> (IMD).

Rack sections <NUM> may be frame structures <NUM> arranged preferably in rows in the first horizontal direction, preferably equipped with shelves <NUM>, preferably made in the form of channels and/or arranged in horizontal rows along the rack sections one above the other. Thus, forming vertical levels for placing boxes <NUM> which are preferably installed on shelves <NUM> and/or designed to store various materials (goods, items). In an example, as shown in <FIG> and <FIG>, the number of rack units <NUM> along the first direction may be six, and the height of the sections n is may be four storage levels of the boxes <NUM>. The top-level n (i.e., the 4th in this example) partially forms a picking area.

Obviously, the number of rack units and their length may be determined by the dimensions of the storage system and/or the total height of the rack units can vary depending on the specific purpose of the system. It may be determined by its overall performance.

The first transport network <NUM> may include a multi-level intersection driveway <NUM>, which may provide the movement of the TMU <NUM> in the first horizontal direction, along the rack sections <NUM> as well as the exit and intersection in the second perpendicular direction. In addition, the transport network <NUM> may include the lower parts of the shelves <NUM>. Along those, the TMU <NUM> can move in the second horizontal direction. Multilevel intersections <NUM> may be located under each storage level of boxes <NUM> and/or docked with shelves <NUM>, preferably so as to provide TMU <NUM> access to any box <NUM> stored on a given horizontal storage level in preferably any rack section <NUM>. The first transport network <NUM> may be shared with rack sections <NUM> provide storage for boxes <NUM> and/or for their capture and/or movement within the system using TMU <NUM>. Moreover, taking and/or installing boxes <NUM> on shelves <NUM> is carried out by approaching TMU <NUM> under the box from below.

The ramp group <NUM> may be an inclined track <NUM> which may connect different levels of the first transport network <NUM> (first rail tracks) of rack sections <NUM> in such a way that the TMU <NUM> can preferably move along them similarly to horizontal movement in the second direction. The inclined track <NUM> may start and/or end directly from the multi-level intersection driveways <NUM> so that the beginning and end of one inclined track <NUM> may be at different levels of the transport network <NUM>.

Preferably, the ramp group <NUM> may be designed to provide independent movement of at least one TMU <NUM> between all levels of the multi-level transport network <NUM>. The combination of the ramp group <NUM> with the multi-level transport network <NUM> provides access to each TMU <NUM> to any box <NUM> located in the system <NUM>.

The second transport network <NUM> is preferably designed to move the executive mobile devices <NUM> through it which are preferably designed to handle the contents of boxes <NUM>, located directly below the transport network <NUM>. The executive mobile devices <NUM> is located, preferably above the upper-level n of the system. The second transport network may comprise at least one parallel pair of tracks <NUM> which are preferably placed above the frame structures <NUM> so as to provide unimpeded access from above to the contents of the boxes <NUM> preferably arranged on the shelves <NUM> or transported on the TMU <NUM> under them. The preferred location of the second transport network <NUM> is generally possible at any height which is sufficient for transport mobile devices <NUM> with boxes <NUM> installed on them to pass under it along the first transport network <NUM>.

Obviously, the number of tracks <NUM> and their length is determined by the size of the warehouse system and is mainly determined by its overall capacity. It is also obvious that a pair of tracks <NUM> can be at such a distance from each other to allow one IMU <NUM> to access more than one row of storage boxes <NUM> in the first horizontal direction.

Terminal <NUM> is preferably designed to input and output boxes <NUM> and their contents to system <NUM>. Terminal <NUM> is preferably located at a comfortable height for use, e.g. by a person, thus at ground level or up to <NUM>. The terminal can be located on either side of the system <NUM>, including the side of the ramps <NUM>. In the proposed example, the terminal is preferably docked from the back of the system to the outermost section <NUM> approximately in the middle of it in the first horizontal direction. The transfer of boxes <NUM> to the terminal is preferably carried out from the first or second level of the first transport network <NUM> using the TMU <NUM>. The terminal can be controlled from the system control module <NUM> via the wired interface <NUM>.

Transport mobile devices <NUM> may be designed to self-pick and/or install at least one box <NUM> from the shelves <NUM> and/or transport them along the first transport network <NUM> and/or groups of ramps <NUM> between any two storage locations of the boxes in the system and to the terminal <NUM>.

As shown in <FIG>, the transport mobile device <NUM> may include a lift table <NUM> which may be designed to accommodate and/or transport the box <NUM>. It may comprise two groups of drive wheels <NUM> and <NUM> which may be designed to interact with the railways of the first transport network <NUM>. Groups of wheels <NUM> and <NUM> may have the ability to move vertically relative to each other, alternately being leading. Thus, a group of wheels <NUM> may serve to move the device in a first horizontal direction and/or the group of wheels <NUM> in the second horizontal direction and/or for moving along the ramps <NUM>.

The structure of the TMU <NUM> may be made in such a way that an empty device with a lifting table <NUM> in the lower position, without a box <NUM> on the lifting table, can travel in a second horizontal direction along the shelves <NUM> with boxes <NUM> standing there, below/under the shelved boxes.

The transport mobile device can be controlled in any known manner. In particular, an embedded industrial controller <NUM> can be used for control, which has preferably a wireless interface <NUM> for communication with the central processor <NUM> of the automatic system. The controller <NUM> may control the drivers <NUM> for the drives of the wheels <NUM> and/or <NUM> to travel along the track of the first transport network <NUM> preferably in two directions and/or the driver <NUM> of the vertical position of the wheels <NUM>, <NUM> and/or the state of the lift table <NUM>.

As shown in <FIG>, <FIG> and <FIG>, the executive mobile device <NUM> may comprise a housing <NUM> having a transport platform <NUM> which may be designed to accommodate materials while moving and/or a window <NUM> that provides access to the contents of the boxes <NUM> underneath the device. In addition, the mobile device <NUM> may include marching wheels <NUM>.

These wheels may be designed to interact with the track <NUM> of the second transport network <NUM>. The mobile device <NUM> may include a <NUM>-axis manipulator <NUM> with a gripper <NUM> (e.g., pneumatically actuated).

The executive mobile device <NUM> can also be controlled in any known manner. In particular, a built-in industrial controller <NUM> can be used for control, which may have a wireless interface <NUM> for communication with the central processor <NUM> of the automatic system. The controller <NUM> may control the drivers <NUM> of the wheel drives <NUM> for movement on the second track <NUM> and/or for precise positioning relative to the boxes <NUM>, preferably standing directly under the second transport network <NUM>. Also, the controller <NUM> may control the drivers <NUM>, <NUM> and <NUM> of the movement of the manipulator <NUM> with the gripper <NUM>.

The manipulator <NUM> may have a machine vision system for accurately positioning the gripper <NUM> relative to the desired material. The material may be located in the boxes <NUM> or on the transport platform <NUM>. The design of the manipulator <NUM> may be made in such a way that the gripper <NUM> can be lowered to the first storage level of the boxes <NUM> (in this particular example, the fourth level, counting from the bottom), for example with a telescopic rod. The processing of data from the machine vision system and/or control of the manipulator <NUM> with the gripper <NUM> may be carried out by the controller <NUM>.

Obviously, the width and length of the body <NUM> of the actuator <NUM> may provide simultaneous access to the three-axis manipulator <NUM> with the gripper <NUM> to several boxes <NUM> at once. The boxes can be placed under the track <NUM> corresponding to the body <NUM> in both the first and second horizontal directions.

The initial loading of an automatic storage system can be carried out in different ways depending on its purpose. For example, terminal <NUM> can fill the system while it receives palletized materials from suppliers.

In this case, the system boot process may include the following sequence of actions:.

Similar to the system boot process, it unloads from the system with the preferred difference that TMU <NUM> bring boxes <NUM> with goods to terminal <NUM> and/or returns them to the storage system, preferably empty. The rest of the algorithm may be as described above.

A generalized kit formation process is depicted in block diagram form in <FIG>.

Step <NUM>: The order processing unit <NUM> of the control module <NUM> may receive information about the need to generate a set of materials.

Step <NUM>: Based on the information received, the central processor <NUM> may determine the ability to fulfill the order with one first executive mobile device (IMD). that is, whether all ordered materials are in its picking area. If possible, step <NUM> is performed, otherwise, step <NUM> is performed.

Step <NUM>: The first transport mobile device <NUM> may place an empty target box <NUM> on the upper storage level in the picking area of the first IMD <NUM>.

Step <NUM>: After the empty target box is installed, the first executive mobile device <NUM> may proceed to build the kit by transferring materials from the donor boxes to the target box. To do this, preferably follow at least some of the following steps:.

Step <NUM>: The controller <NUM> of the first executive mobile device <NUM> may be on commands from the central processor <NUM>. The commands may be received via wireless interface <NUM> and/or may control the drives <NUM> of the wheels <NUM> such that the mobile device <NUM> moves along the second track <NUM> and is positioned by the window <NUM> exactly above the box <NUM> with the first ordered material. In this case, this box must be in the picking area.

Step <NUM>: Controller <NUM> may control the actuators <NUM>, <NUM> and <NUM> of the vision arm <NUM> to position the gripper <NUM> over the desired material in the donor box.

Step <NUM>: Manipulator <NUM>, using gripper <NUM>, may take material from the box and move it to transport platform <NUM>.

Step <NUM>: The controller <NUM> may control the wheel drives <NUM> such that the mobile device <NUM> moves along the second track <NUM> and is positioned by the window <NUM> (exactly) over the target acceptor box <NUM>.

Step <NUM>: Manipulator <NUM> uses gripper <NUM> to take material from transport platform <NUM> and to transfer it to the ordered kit box in a box located on shelves <NUM>, located in the picking zone of the first IMU <NUM>. If necessary, picking in a box is also possible which is located on the transport mobile device <NUM>, standing in the picking area of the IMU <NUM>.

Step <NUM>: Next, a check may be performed that the bundling has been completed. The check can be performed by both the central processor <NUM> and/or the controller <NUM> of the first executive mobile device. If the kit is formed (check positive), then step <NUM> is performed, if not, then step <NUM>.

Step <NUM>: Determine whether to dispense the generated kit. If the delivery of the kit is required immediately, then step <NUM> is performed, if not, then step <NUM> is performed.

Step <NUM>: Transport mobile device <NUM> may move the assembled box to the temporary storage area.

Step <NUM>: Transport mobile device <NUM> moves the assembled box to terminal <NUM>.

Step <NUM>: The formed set of materials (kit) is taken from the box in the terminal <NUM> or, if necessary, the box with the whole set is taken.

Step <NUM>. The central processor <NUM> of the automatic system may determine the number of boxes required to fulfill the order. If one box is required, then step <NUM> is performed, if more boxes are required, then step <NUM>.

Step <NUM>: The first and second transport mobile devices <NUM> may place empty target boxes <NUM> as close as possible to the midpoints of the respective picking areas.

Step <NUM>: After the empty target boxes are installed, the first and second executive mobile devices <NUM> begin to build the kit by transferring materials from the donor boxes to the target boxes. In this case, actions similar to steps <NUM> - <NUM> are performed for each executive mobile device.

Step <NUM>: Next, a check can be made that the bundling has been completed. If the set is formed (check positive), then step <NUM> is performed, if not, then step <NUM> is performed.

Step <NUM>: Preferably determine whether to dispense the generated kit. If the dispensing of the kit is required immediately, then step <NUM> is performed, if not, then step <NUM> is performed.

Step <NUM>: The first and second transport mobile devices <NUM> preferably move the assembled boxes to the temporary storage area.

Step <NUM>: The first and second transport mobile devices <NUM> may move the assembled boxes to the terminal <NUM>.

Step <NUM>: The first transport mobile device <NUM>, upon command from the CPU <NUM>, may take an empty target box <NUM>. Target box <NUM> may be intended for placing ordered materials in the picking area of the first executive mobile device <NUM>.

Step <NUM>: The first executive mobile device <NUM> may proceed to form the kit by transferring materials from the donor boxes to the target box on board the TMU <NUM>. This is done in the same way as in steps <NUM> through <NUM>.

Step <NUM>: Next, a check may be conducted that the bundling has been completed. If the first executive mobile device <NUM> has transferred all of the materials, then step <NUM> is performed, if not, then step <NUM>.

Step <NUM>: Upon completion of the operation of the first executive mobile device <NUM>, the transport mobile device <NUM>, upon command of the central processor <NUM>, may move the target box to the row with the second executive mobile device <NUM>.

Step <NUM>: After the target box has been moved, the second executive mobile device <NUM> may proceed to build the kit by transferring materials from the donor boxes to the target box. This performs the same steps as steps <NUM> through <NUM>.

Step <NUM>: Next, a check may be conducted that the bundling has been completed. If the second executive mobile device <NUM> has transferred preferably all of the materials (complete formation of the package), then step <NUM> is performed, if not, then step <NUM>.

Step <NUM>: Determine whether to dispense the generated kit. If dispensing the kit is required (immediately), then step <NUM> is performed, if not, then step <NUM> is performed.

Step <NUM>: Transport mobile device <NUM> preferably moves the assembled box to the temporary storage area.

Step <NUM>: Transport mobile device <NUM> preferably moves the assembled box to terminal <NUM>.

During the operation of the claimed system, a situation may arise in which a significant proportion of the work on the formation of orders will fall on one executive mobile device <NUM> while the rest of the executive mobile devices <NUM> will be idle. To ensure that all devices in the system are loaded evenly, the following steps are taken.

A portion of the donor boxes from the picking area of the first "overloaded" executive mobile device <NUM> may be transported by means of transport mobile devices <NUM> to the picking areas of other, "underloaded" executive mobile devices <NUM>. After that, other executive devices <NUM> begin to operate with their contents, thus thereby, unloading the "overloaded" device <NUM>, parallelizing the work.

In the system, the stored materials may be ranked as popular (that is, which are in constant high demand) and slow (not often ordered). Popular materials are stored in the upper storage levels of the system, slow moving materials - in the lower ones. Since there is no point in storing slow-moving materials in the picking areas due to their rare use in ordered sets direct picking may be carried out from the boxes containing them, with an instant reverse movement of them back "to the bottom" of the system.

To this end, the transport mobile device <NUM> may take on board a box of slow goods from one of the lower storage levels of the system. Moves it to the picking area of one of the executive mobile devices <NUM> without unloading and/or after the picking process, returns it to its place, down.

While various aspects of carrying out the claimed invention have been described herein, those skilled in the art will appreciate that other approaches to carrying out the present invention are possible. The various aspects and implementation of the present invention are set forth herein for illustrative purposes and are not intended to be limiting. Moreover, the scope of protection of the present invention is indicated in the following claims.

Claim 1:
A system for storing and organizing materials comprising:
at least two tiers (<NUM>) arranged on top of each other comprising a first tier and at least one further tier that is arranged below the first tier, each of which comprises a plurality of storage places arranged in rows in two horizontal directions perpendicular to each other, a plurality of boxes accommodated individually in these storage places and at least two, preferably all, tiers comprise the storage places;
wherein a first transport network (<NUM>) with a plurality of first rail tracks (<NUM>) crosswise connected and horizontally arranged within each tier is provided, the first rail tracks are adapted to accommodate mobile transporting devices (<NUM>) for their transportation;
wherein each of the plurality of mobile transporting devices (<NUM>) is adapted to pick up and accommodate at least one box from a storage place and move the accommodated box along the respective first rail tracks (<NUM>) towards, away and/or between the storage places of the tier (<NUM>), wherein the first transport network of each tier is also provided below the position of a storage place and wherein mobile transport devices by themselves are adapted to pass through below a stored box in a storage place on the first transport network from one side of the storage place to the opposite side;
wherein at least partially above the first tier (<NUM>) an assembly area is provided; the assembly area comprises a second transport network (<NUM>), with a plurality of second rail tracks (<NUM>) oriented horizontally and parallel to each other, adapted to accommodate mobile actuating devices (<NUM>) along them for their transportation,
wherein each of the plurality of mobile actuating devices (<NUM>) is provided with a gripper adapted to grab and transfer at least some content of a box within the first and/or any further tier arranged below the first tier, while such box and one of the mobile actuating devices (<NUM>) are arranged above each other.