Patent Description:
The Applicant's already known AutoStore system is a storage system comprising a three dimensional storage grid wherein storage bins are stacked on top of each other to a certain height.

The storage grid is constructed as aluminium columns interconnected by top rails. A number of vehicles, or robot vehicles, are arranged on the top rails and may move horizontally on top of the storage grid.

Each vehicle is equipped with a lift for picking up, carrying, and placing bins that are stored in the storage grid.

The system also comprises delivery and/or supply stations, where one or several items are picked out from the storage bin or where one or several items are filled into the storage bin.

When an item of a product type stored in a storage bin is to be retrieved from the storage grid, the robot vehicle is arranged to pick up the storage bin containing that product type and then transport it to a bin lift device The bin lift device is transporting the storage bin to the delivery and/or supply stations, where the item of the product type is retrieved from the storage bin. The storage bin with the remaining items of the product type is thereafter returned to the storage grid by means of a bin lift device and a robot vehicle.

The same procedure is used for refilling items into the storage grid. First, items are filled into a storage bin at a delivery and/or supply station. The bin lift device is then lifting the storage bin up to the upper level where a robot vehicle is transporting the storage bin into its correct position within the storage grid.

A storage control and communication system may be used to monitor inventory, location of storage bins (within storage grid and/or during transport), charge level, etc. The storage control and communication system may also comprise, or may be provided in communication with, a control system for controlling the robot vehicles in order to avoid collision.

It has been found that relatively long time is used by the storage system to transport storage bins from the top of the grid and to the delivery and/or supply stations. Hence, it is an object of the invention to provide a more time efficient storage system.

<CIT> discloses a storage system for storing product items according to the preamble of claim <NUM>. <CIT> describes systems, methods, and machine-executable coded instruction sets for the fully- and/or partly automated handling of goods. In particular, the disclosure is related to the storage and retrieval of containers in systems such as order processing systems.

The present invention relates to a storage system, as defined in claim <NUM>, for storing product items, comprising a grid structure, where the grid structure has a top level. A number of first storage bins is configured to be stored in vertical stacks in the grid structure, where each first storage bin is configured to contain at least one product item;
a vehicle, arranged to move horizontally at the top level of the grid structure, and further arranged to pick up, carry, and place the first storage bins at desired locations within the grid structure. The invention is characterized in that.

It should be noted that even though each first storage bin is configured to contain at least one product item, it is fully possible to store empty first storage bins in the storage grid.

Aspects of the invention are apparent from the enclosed dependent claims.

Embodiments of the invention will be described in the following with reference to the enclosed drawings, where:.

It is now referred to <FIG>. Here it is shown a storage system <NUM> comprising a grid structure <NUM> for storing products in storage bins <NUM>. Each storage bin <NUM> is configured to contain one or several product items.

As shown in <FIG>, a certain number of the storage bins <NUM> are configured to be stored in vertical stacks within the grid structure <NUM>.

A vehicle <NUM> is arranged to move horizontally at a top level L0 of the grid structure <NUM>, and further arranged to pick up, carry, and place the first storage bins <NUM> at desired locations.

The storage system <NUM> further comprises a delivery and/or supply station <NUM>. The delivery and/or supply station <NUM> is provided on the floor of the building onto which the storage grid <NUM> is arranged. This floor level is denoted Ln, where n is the number of storage bins <NUM> that can be stacked in the storage grid <NUM>. The delivery and/or supply station <NUM> is used to prepare picked product items from the grid structure <NUM> for delivery to a receiver (for example a buyer of a product item). The delivery and/or supply station <NUM> is also used to register product items from a supplier (for example a manufacturer of product items) before placing the product items within the grid structure <NUM>.

It should be noted that there may be several delivery and/or supply stations <NUM>, and least one of these delivery and/or supply stations <NUM> may be separated into delivery stations and supply stations, where the delivery stations handle product items picked from the grid structure and where the supply stations handle product items to be placed into the grid structure.

The system in <FIG> also comprises a bin lift device <NUM>, arranged to transport the storage bins <NUM> between the top level L0 of the grid structure <NUM> and the delivery and/or supply station <NUM>. In <FIG> this transport is shown in a vertical direction.

The storage system <NUM> shown in <FIG> is considered to be prior art.

In the following, the term "first storage bin" is used for the storage bins <NUM> stored in the grid structure <NUM> and which are to be transported to the delivery and/or supply station <NUM> via the bin lift device <NUM>.

It is now referred to <FIG> and <FIG>. As in <FIG>, the storage system <NUM> comprises a storage grid <NUM> with stacks of storage bins <NUM>. Levels L0, L1, L2 - Ln are indicated.

The vehicle <NUM> is also shown. The particular vehicle <NUM> shown in <FIG> is considered known. The prior art vehicle <NUM> may travel in the horizontal direction (along a horizontal x-axis and a horizontal y-axis as indicated in <FIG>) on level L0 of the grid structure <NUM>. The vehicle <NUM> comprises a lift (not shown) for picking up storage bins <NUM> and for transporting the storage bins <NUM> to desired locations within the grid structure <NUM> such as.

For example, if a desired product item is located in a storage bin <NUM> at level L3, and below other storage bins <NUM>, the vehicle <NUM> may first move the upper storage bins <NUM> positioned directly above the storage bin <NUM> to be picked (at levels L2 and L1) to other available locations on top of the grid structure in order to get access to the desired storage bin <NUM> at level L3.

It should be noted that the particular design of the prior art vehicle <NUM> shown in <FIG> renders temporary storage of storage bins <NUM> on level L0 possible. In <FIG>, it is shown a storage bin <NUM> at a location A located on level L0. Of course, this storage bin <NUM> at location A will prevent access to the storage bins directly beneath this storage bin. Moreover, the storage bin <NUM> at location A will also represent an obstacle to moving vehicles <NUM>.

In <FIG> it is disclosed that the storage system <NUM> further comprises a robot device <NUM>.

The robot device <NUM> comprises a base <NUM> connected to a movable arm <NUM>. In <FIG>, it is shown that the movable arm <NUM> comprises a first arm section 72a connected to the base <NUM> and a second arm section 72b connected to the first arm section 72a via a pivotal joint 72c. The robot device <NUM> further comprises a picking mechanism <NUM> at the outer end of the second arm section 72b.

It should be noted that the robot device <NUM> itself is considered to be known, as several such types of robots are commercially available.

In <FIG> it is shown that the base <NUM> of the robot device <NUM> is located at a distance above level L0.

According to the present invention, the robot device <NUM> is configured to move a storage item <NUM> between a first location A and a second location B by means of its picking mechanism <NUM> (<FIG>). In addition, the robot device <NUM> may be configured to move the entire first and/or second storage bin <NUM>; <NUM> by means of its picking mechanism <NUM>.

The robot device <NUM> may during use be located with its movable arm <NUM> above a top level L0 of the storage grid <NUM> or at a level below the top level L0, for example level L1. Hence, according to the present invention the first location A is the location of a first storage bin <NUM> stored at the top level L0 or at the level L1 directly below the top level L0 of the storage grid <NUM>. Again, a storage bin <NUM> at level L1 is only accessible if there is no storage bin <NUM> at level L0 directly above it (at the same x- and y-location).

The robot device <NUM> is provided in communication with a vehicle control system controlling the vehicles <NUM> in order to for example avoid collision between the vehicles <NUM> and the robot device <NUM>. It should be noted that there are several ways of achieving this - there may be one main control system which controls the robot device <NUM> and each of the vehicles <NUM> in detail. For example, a main control system may define a time slot for vehicle movement within an area close to the robot device <NUM>, in which time slot the robot device <NUM> is instructed to move its arm to a position where no collision may occur. Then, another time slot may be defined in which the vehicles <NUM> are instructed to stay away from the area close to the robot device <NUM>. Alternatively, the control system may be of a type where the robot device <NUM> and the vehicles <NUM> are more or less autonomous. For example, they may be equipped with sensors connected to an internal control system provided on each vehicle/robot <NUM>.

The above vehicle control system may be part of, or may be provided in signal communication with, a storage control and communication system as mentioned above.

In <FIG> and <FIG>, the first location A is the location of a first storage bin <NUM> stored in or on the storage grid <NUM>, while the second location B is a location of a conveyor system generally referred to by reference number <NUM>. The conveyor system <NUM> is arranged adjacent to the storage grid <NUM>. The second location B may be the location of a second storage bin <NUM> arranged on the conveyor system <NUM> as shown in <FIG> and <FIG> or indicate the location of the conveyor system <NUM> itself.

The conveyor system <NUM> may comprise one conveyor belt, conveyor chain or any other type of conveyors suitable for transporting a product item <NUM> or a second storage bin <NUM> containing one or several storage items <NUM>. The conveyor system <NUM> may also comprise several such conveyors.

The conveyor system <NUM> may be configured to transport the product item <NUM> or the second storage bin <NUM> containing product items <NUM> to the delivery and/or supply station <NUM>, thereby acting as the robot lift <NUM> mentioned earlier.

In <FIG>, it is shown that the conveyor system <NUM> close to the robot device <NUM> is provided at a height Hc equal to, or above, a height HL1 of the level L1 directly below the top level L0. Of course, other parts of the conveyor system <NUM> may be located at lower heights.

The present invention makes it possible to increase the efficiency of the storage system <NUM> by avoiding, entirely or partially, the transportation of the first storage bins <NUM> to the delivery and/or supply station <NUM> via the bin lift device <NUM>.

Alternatively, the invention makes it possible to arrange delivery and/or supply station(s) <NUM> at other levels, for example at a height corresponding to the height indicated in <FIG>, and at a location in a room situated adjacent to the room in which the storage grid <NUM> is arranged.

As mentioned above, the first storage bins <NUM> have a design adapted for being stacked above each other in the grid structure <NUM> and for being transported by the vehicles <NUM> and the bin lift device <NUM>.

However, the second storage bins <NUM> may also be of a different type. The second storage bins <NUM> may be a cardboard box used for dispatching the product item(s) <NUM> to the receiver, for example the above mentioned buyer of the product item(s) <NUM>. Accordingly, the robot device <NUM> may perform some or all of the working operations presently performed more or less manually at the delivery and/or supply station <NUM>. For some types of products, only the closing operation of the cardboard box and/or the provision of an address label onto the cardboard box remain.

Alternatively, the second storage bins <NUM> are of substantially the same type as the first storage bins <NUM>, where the robot device <NUM> is picking several of, or all of the product items of an order to one receiver. The second storage bins <NUM> are then transported via the conveyor system <NUM> to the delivery and/or supply station <NUM>, where the order is finished by repackaging the product items <NUM> from the second storage bin <NUM> into a cardboard box. This may be necessary for product items <NUM> which require special care, for example frangible product items <NUM>. The operation is still more efficient since all product items <NUM> of one order is arriving at the delivery and/or supply station <NUM> at the same time.

It is once again referred to <FIG> and <FIG>. Here it is shown that the conveyor system <NUM> comprises a first conveyor 90a transporting second storage bins <NUM> in a first direction (indicated by arrow x in <FIG>) and three conveyors 90b, 90c, 90d subsequently transporting storage bins <NUM> in parallel in a second direction (indicated by arrow y in <FIG>).

It is now referred to <FIG>. Here, a first robot arm reachable area is indicated by a dashed box A1 in the grid structure <NUM> and a second robot arm reachable area is indicated by a dashed box B1 outside of the grid structure <NUM>. A product item <NUM> at location A is indicated within a first storage bin <NUM> within area A1 and a location B for the product item <NUM> is indicated within a second storage bin <NUM> within area B1. As shown, the second area B1 is located on the three parallel conveyors 90b, 90c, 90d, close to the robot device <NUM>.

In <FIG>, the dashed circle C is indicating the maximum reach of the picking mechanism <NUM> of the robot device <NUM>. Of course, the number of first storage bins <NUM> within the first area A1 and the number of second storage bins <NUM> within the second area B1 may vary based on the size of the robot device <NUM> and the size of the storage bins <NUM>, <NUM>.

Hence, the storage control and communication system is configured to control the vehicles <NUM> to place a plurality of first storage bins <NUM> within the first robot arm <NUM> reachable area A1 of the storage grid <NUM> and then to control the robot device <NUM> to move the product item <NUM> from at the first storage bin <NUM> in the first robot arm <NUM> reachable area A1 of the storage grid <NUM> to the second storage bin <NUM> placed in the second robot arm <NUM> reachable area B1 outside of the storage grid <NUM>.

When all product items <NUM> are placed into the second storage bin <NUM>, the bin <NUM> is transported via the conveyor 90b to the next station for further handling (dispatching, repackaging or other operations at the delivery and/or supply station <NUM>, etc). Empty second storage bins <NUM> are supplied via conveyor 90a, and the robot device <NUM> may move a second storage bin <NUM> from the first conveyor 90a to the free space within the second area B1.

Alternatively, the conveyors 90b, 90c, 90d may transport empty second storage bins <NUM> towards the robot device <NUM> (opposite direction of arrow y) and may move the second storage bins <NUM> with product items <NUM> onto the first conveyor 90a for further handling.

Alternatively, the robot device <NUM> is used to supply the storage grid <NUM> with product items <NUM>. Here, the storage bins <NUM> may arrive to the robot device <NUM> and the robot device <NUM> is used to fill first storage bins <NUM> which then are moved into the desired location within the storage grid <NUM> by means of the vehicles <NUM>.

According to the first embodiment, the prior art bin lift device <NUM> may be partially or entirely omitted in the storage system. This is highly advantageous since the bin lift device <NUM> in some prior art storage systems may have a height of <NUM> meters or more, which in total consumes a considerable amount of the total transportation time. An omission of a prior art bin lift device <NUM> also have the potential of mitigating logistic problems related to for example efficient sorting of product items <NUM>.

It is now referred to <FIG>. The second embodiment has many features in common with the first embodiment above, and the same reference numbers has been used for those common features. For efficiency, only the differences between the second and first embodiment are described here.

In the second embodiment, the conveyor system <NUM> comprising a first conveyor 90a and a second conveyor 90b are arranged in parallel. They may move in the same direction or in opposite directions. As in <FIG> the first robot arm reachable area A1 are indicated in the storage grid <NUM> and second robot arm reachable area B1 are indicated on the first and second conveyor 90a.

It is now referred to <FIG>. The third embodiment has many features in common with the first embodiment above, and the same reference numbers has been used for those common features. For efficiency, only the differences between the third and first embodiment are described here.

In the third embodiment, the robot device <NUM> is fixed to the grid structure <NUM> and can be surrounded by vertical stacks of storage bins <NUM>. Here, the conveyor system <NUM> is provided above, not on the side of, the storage grid <NUM>. Moreover, the conveyor system <NUM> comprises only one conveyor 90a. In this way, also central parts of the storage grid <NUM> can be within a robot arm reachable area. In <FIG> a first robot arm reachable area A1 is indicated in the storage grid <NUM>, and a second robot arm reachable area B1 is indicated on the conveyor 90a.

Preferably, the conveyor system <NUM> is provided at a height HV corresponding to the height of a vehicle <NUM> (see dashed line in <FIG>) above the top level L0. Hence, vehicles <NUM> may pass under the conveyor system <NUM>.

The base <NUM> of the robot device <NUM> is here supported by an iron girder, or supporting beam above the grid structure <NUM>, such as a girder/beam supporting the roof of the building under which the storage grid <NUM> is provided. Such a robot device <NUM> may be fixed at one specific location above the grid structure <NUM>, or be moveable by for example sliding on said girders / beams.

In such an embodiment, it is also possible to provide the conveyor system <NUM> with a conveyor 90a at a height HV corresponding to or above the height of a vehicle <NUM>, so that the vehicle <NUM> can pass under the conveyor belt. It is also possible to provide the conveyor system <NUM> with a conveyor 90b within the grid <NUM>, for example at approximately level L1 or L2.

It should be noted that the storage system <NUM>, in all of the above embodiments, will be adapted to its intended use. The storage system <NUM> may comprise one or several such robot devices <NUM>. The robot devices <NUM> may be provided on the side of the storage grid as in the first and second embodiments above, and/or integrated into the storage grid as in <FIG>, or above the storage grid as in <FIG>.

The storage control and communication system may also be configured according to its intended use. It may for example be configured to analyze a plurality of picking orders and then determine the most frequently demanded product items <NUM> from the picking orders. Based on this, it may configure or control the vehicles <NUM> to place the first storage bins <NUM> containing the most frequently demanded product items <NUM> in the first area A1.

Moreover, the storage control and communication system may further be configured to control the robot device <NUM> to move product items <NUM> from more than one first storage bin <NUM> in the first robot arm <NUM> reachable area A1 of the storage grid <NUM> to at least one second storage bin <NUM> placed in the second robot arm <NUM> reachable area B1 outside of the storage grid <NUM>. As described above, the robot device <NUM> will then be able to carry out a picking order entirely or partially and hence make the picking operation more efficient.

Claim 1:
A storage system (<NUM>) for storing product items (<NUM>), comprising
a grid structure (<NUM>), where the grid structure has a top level (L0);
a number of first storage bins (<NUM>) configured to be stored in vertical stacks in the grid structure (<NUM>), where each first storage bin (<NUM>) is configured to contain at least one product item (<NUM>);
a vehicle (<NUM>), arranged to move horizontally at the top level (L0) of the grid structure, and further arranged to pick up, carry, and place the first storage bins (<NUM>) at desired locations within the grid structure (<NUM>);
characterized in that
- the storage system (<NUM>) further comprises a robot device (<NUM>) comprising a movable arm (<NUM>) with a picking mechanism (<NUM>) in one end thereof,
- the robot device (<NUM>) is configured to move a product item (<NUM>) between a first location (A) and a second location (B) by means of its picking mechanism (<NUM>);
- the first location (A) is the location of a first storage bin (<NUM>) stored at the top level (L0) of the storage grid (<NUM>) or a level (L1) directly below the top level (L0).