Patent Description:
<FIG> discloses a prior art automated storage and retrieval system <NUM> with a framework structure <NUM> and <FIG>, <FIG> disclose three different prior art container handling vehicles <NUM>, <NUM>, <NUM> suitable for operating on such a system <NUM>.

The framework structure <NUM> comprises upright members <NUM> and a storage volume comprising storage columns <NUM> arranged in rows between the upright members <NUM>. In these storage columns <NUM> storage containers <NUM>, also known as bins, are stacked one on top of one another to form container stacks <NUM>. The members <NUM> may typically be made of metal, e.g. extruded aluminum profiles.

The framework structure <NUM> of the automated storage and retrieval system <NUM> comprises a rail system <NUM> arranged across the top of framework structure <NUM>, on which rail system <NUM> a plurality of container handling vehicles <NUM>, <NUM> may be operated to raise storage containers <NUM> from, and lower storage containers <NUM> into, the storage columns <NUM>, and also to transport the storage containers <NUM> above the storage columns <NUM>. The rail system <NUM> comprises a first set of parallel rails <NUM> arranged to guide movement of the container handling vehicles <NUM>, <NUM> in a first direction X across the top of the frame structure <NUM>, and a second set of parallel rails <NUM> arranged perpendicular to the first set of rails <NUM> to guide movement of the container handling vehicles <NUM>, <NUM> in a second direction Y which is perpendicular to the first direction X. Containers <NUM> stored in the columns <NUM> are accessed by the container handling vehicles <NUM>, <NUM> through access openings <NUM> in the rail system <NUM>. The container handling vehicles <NUM>, <NUM> can move laterally above the storage columns <NUM>, i.e. in a plane which is parallel to the horizontal X- Y plane.

Each prior art container handling vehicle <NUM>, <NUM>, <NUM> comprises a vehicle body 201a, 301a, 401a and first and second sets of wheels 201b, 201c, 301b, 301c, 401b, 401c which enable lateral movement of the container handling vehicles <NUM>, <NUM>, <NUM> in the X direction and in the Y direction, respectively. In <FIG>, two wheels in each set are fully visible. The first set of wheels 201b, 301b, 401b is arranged to engage with two adjacent rails of the first set <NUM> of rails, and the second set of wheels 201c, 301c, 401c is arranged to engage with two adjacent rails of the second set <NUM> of rails. At least one of the sets of wheels 201b, 201c, 301b, 301c, 401b, 401c can be lifted and lowered, so that the first set of wheels 201b, 301b, 401b and/or the second set of wheels 201c, 301c, 401c can be engaged with the respective set of rails <NUM>, <NUM> at any one time.

Each prior art container handling vehicle <NUM>, <NUM>, <NUM> also comprises a lifting device <NUM>, <NUM> (visible in <FIG>) having a lifting frame part 304a, 404a 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>, <NUM> comprises one or more gripping/engaging devices which are adapted to engage a storage container <NUM>, and which gripping/engaging devices can be lowered from the vehicle <NUM>, <NUM>, <NUM> so that the position of the gripping/engaging devices with respect to the vehicle <NUM>, <NUM>, <NUM> can be adjusted in a third direction Z (visible for instance in <FIG>) which is orthogonal the first direction X and the second direction Y. Parts of the gripping device of the container handling vehicles <NUM>, <NUM> are shown in <FIG> and <FIG> indicated with reference number. The gripping device of the container handling device <NUM> is located within the vehicle body 201a in <FIG>.

Conventionally, and also for the purpose of this application, Z=<NUM> identifies the uppermost layer available for storage containers below the rails <NUM>, <NUM>, i.e. the layer immediately below the rail system <NUM>, Z=<NUM> the second layer below the rail system <NUM>, Z=<NUM> the third layer etc. In the exemplary prior art disclosed in <FIG>, Z=<NUM> identifies the lowermost, bottom layer of storage containers. Similarly, X=<NUM>. n and Y=<NUM>. The container handling vehicles <NUM>, <NUM>, <NUM> can be said to travel in layer Z=<NUM>, and each storage column <NUM> can be identified by its X and Y coordinates. Thus, the storage containers shown in <FIG> extending above the rail system <NUM> are also said to be arranged in layer Z=<NUM>.

The storage volume of the framework structure <NUM> has often been referred to as a grid <NUM>, where the possible storage positions within this grid are referred to as storage cells. Each storage column may be identified by a position in an X- and Y-direction, while each storage cell may be identified by a container number in the X-, Y- and Z-direction.

Each prior art container handling vehicle <NUM>, <NUM>, <NUM> comprises a storage compartment or space for receiving and stowing a storage container <NUM> when transporting the storage container <NUM> across the rail system <NUM>. The storage space may comprise a cavity arranged internally within the vehicle body 201a as shown in <FIG> and <FIG> and as described in e.g. <CIT> and <CIT>.

The cavity container handling vehicles <NUM> shown in <FIG> may have a footprint that covers an area with dimensions in the X and Y directions which is generally equal to the lateral extent of a storage column <NUM>, e.g. as is described in <CIT>.

The term 'lateral' used herein may mean 'horizontal'.

Alternatively, the cavity container handling vehicles <NUM> may have a footprint which is larger than the lateral area defined by a storage column <NUM> as shown in <FIG> and as disclosed in <CIT> or <CIT>.

Each rail may comprise one track, or each rail may comprise two parallel tracks; in other rail systems <NUM>, each rail in one direction may comprise one track and each rail in the other perpendicular direction may comprise two tracks. The rail system may also comprise a double track rail in one of the X or Y direction and a single track rail in the other of the X or Y direction. A double track rail may comprise two rail members, each with a track, which are fastened together.

In <FIG>, columns <NUM> and <NUM> are such special-purpose columns used by the container handling vehicles <NUM>, <NUM>, <NUM> to drop off and/or pick up storage containers <NUM> so that they can be transported to an access station (not shown) where the storage containers <NUM> can be accessed from outside of the framework structure <NUM> or transferred out of or into the framework structure <NUM>. For example, the storage containers <NUM> may be placed in a random or a dedicated column <NUM> within the framework structure <NUM>, then picked up by any container handling vehicle and transported to a port column <NUM>, <NUM> for further transportation to an access station. The transportation from the port to the access station may require movement along various different directions, by means such as delivery vehicles, trolleys or other transportation lines.

In <FIG>, the first port column <NUM> may for example be a dedicated drop-off port column where the container handling vehicles <NUM>, <NUM> can drop off storage containers <NUM> to be transported to an access or a transfer station, and the second port column <NUM> may be a dedicated pick-up port column where the container handling vehicles <NUM>, <NUM>, <NUM> can pick up storage containers <NUM> that have been transported from an access or a transfer station.

The access station may typically be a picking or a stocking station where product items are removed from or positioned into the storage containers <NUM>. In a picking or a stocking station, the storage containers <NUM> are normally not removed from the automated storage and retrieval system <NUM>, but are, once accessed, returned into the framework structure <NUM>. A port can also be used for transferring storage containers to another storage facility (e.g. to another framework structure or to another automated storage and retrieval system), to a transport vehicle (e.g. a train or a lorry), or to a production facility.

A conveyor system comprising conveyors is normally employed to transport the storage containers between the port columns <NUM>, <NUM> and the access station.

If the port columns <NUM>, <NUM> and the access station are located at different heights, the conveyor system may comprise a lift device with a vertical component for transporting the storage containers <NUM> vertically between the port column <NUM>, <NUM> and the access station.

When a storage container <NUM> stored in one of the columns <NUM> disclosed in <FIG> is to be accessed, one of the container handling vehicles <NUM>, <NUM>, <NUM> is instructed to retrieve the target storage container <NUM> from its position and transport it to the drop-off port column <NUM>. This operation involves moving the container handling vehicle <NUM>, <NUM> to a location above the storage column <NUM> in which the target storage container <NUM> is positioned, retrieving the storage container <NUM> from the storage column <NUM> using the container handling vehicle's <NUM>, <NUM>, <NUM> lifting device (not shown), and transporting the storage container <NUM> to the drop-off port column <NUM>. Alternatively, or in addition, the automated storage and retrieval system <NUM> may have container handling vehicles <NUM>, <NUM>, <NUM> specifically dedicated to the task of temporarily removing storage containers <NUM> from a storage column <NUM>. Once the target storage container <NUM> has been removed from the storage column <NUM>, the temporarily removed storage containers <NUM> can be repositioned into the original storage column <NUM>. However, the removed storage containers <NUM> may alternatively be relocated to other storage columns <NUM>.

When a storage container <NUM> is to be stored in one of the columns <NUM>, one of the container handling vehicles <NUM>, <NUM>, <NUM> is instructed to pick up the storage container <NUM> from the pick-up port column <NUM> and transport it to a location above the storage column <NUM> where it is to be stored. After storage containers <NUM> positioned at or above the target position within the stack <NUM> have been removed, the container handling vehicle <NUM>, <NUM>, <NUM> positions the storage container <NUM> at the desired position. The removed storage containers <NUM> may then be lowered back into the storage column <NUM> or relocated to other storage columns <NUM>.

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

Frequently, an automated storage and retrieval system of the kind described in conjunction with <FIG> is integrated with a retail establishment. More specifically, an automated storage and retrieval system of this kind typically comprises an area where products purchased by the customer are aggregated into standard storage containers of the system and staged, i.e. waiting for a customer delivery procedure to be initiated. One way to deliver these storage containers is to provide a dedicated delivery port close to the checkout counter of the retail establishment. At this delivery port, the storage containers originating from the staging area and containing purchased products are delivered to a waiting customer. As the number of such ports normally is limited in an automated storage and retrieval system, delivery delays frequently occur, especially in peak periods.

Another method to deliver purchased products, especially common in connection with online shopping, is to avoid storage containers altogether in the delivery phase and use conventional parcel lockers. These lockers are standalone kiosks comprising a plurality of locker compartments, typically provided close to customer's domicile, i.e. at a significant distance from the automated storage and retrieval system of the kind described in conjunction with <FIG>. More specifically, purchased products are delivered by a courier transporting, e.g. by means of a lorry, a parcel containing purchased products to a parcel locker and manually inserting this parcel into a suitably sized locker compartment. Once he/she receives a notification that the parcel is delivered to the locker, the customer may collect the parcel. As easily inferred, this method is very labor-intensive. One system of this kind is disclosed in <CIT>.

<CIT>, which the EPO identified in the examination procedure as the "closest prior art" in relation to claim <NUM>, describes, according to its abstract, a system for supplying an enclosure with trolleys or similar, provided more particularly in the passenger cabin of an aircraft and comprising: at least one storage container in which said trolleys are arranged and which is situated in the baggage compartment of said aircraft; a controllable automatic device provided in the baggage compartment of said aircraft and able to move to seize each of said trolleys in said container, by gripping means, and then bring it to said enclosure via a passage formed between the baggage compartment and said enclosure; and a programmable control unit connected to said automatic device and containing the information relative to the position of said trolleys in the container and to the types of products contained in each of them so that, depending on the information transmitted by said unit, said automatic device moves for seizing said corresponding trolley and bringing it from the baggage compartment to said enclosure.

In view of all of the above, it is desirable to provide a solution that solves or at least mitigates one or more of the aforementioned problems belonging to the prior art.

First aspect of the invention relates to an assembly according to claim <NUM>.

By providing an assembly in accordance with the first aspect of the invention, a fully automated solution, i.e. a solution that doesn't require attendance by an operator for product delivery, is obtained. More specifically, container handling vehicles stack goods holders filled with purchased products into storage cells in a usual manner whereby locking mechanism associated with the storage cell is activated. The storage cells containing goods holders are located in an area accessible by customers - a so-called pick-up area. Thus, a customer desiring to collect purchased products only needs to access the pick-up area and deactivate the locking mechanism in order to gain access to the interior of the goods holder and complete the pick-up. The deactivation is normally triggered by the customer using a suitable human-machine-interface in order to provide instructions to a control system associated with the locking mechanism associated with the storage cell.

Second aspect of the invention relates to a storage module according to claim <NUM>.

Such a module obviates the need for a dedicated product-staging area - the purchased products are immediately stored in a module placed in an area that serves as a combined staging area and pick-up area. In a related context, customer waiting times are significantly reduced because once the goods holder is in the storage cell, it is immediately available for pickup.

Also, by virtue of the module in accordance with the second aspect of the invention, all goods holders are at all times accessible for customers such that high pick-up throughput may be achieved.

Typically, the module is detachable and suitable for coupling, e.g. slotting, to a framework structure of an automated storage and retrieval system shown in <FIG>. By way of example, coupling of the module to the automated storage and retrieval system may be effectuated by means of a forklift. As an alternative, the module may be provided with wheels so as to enable manual handling. Regardless of the method used, it is necessary to properly align the module with the system. This may be achieved in various ways well known to the person skilled in the art.

Third aspect of the invention relates to an automated storage and retrieval system according to claim <NUM>.

Hereby, a simple solution for quickly replenishing the module is achieved. More specifically, the remotely operated vehicles operating on the rail system have access from above to the system as well as to the module. If a transfer of goods holder(s), either from the module to the rest of the system, or in the opposite direction, is required, the highly efficient, system-native remotely operated vehicles are employed.

Fourth aspect of the invention relates to a method of accessing the interior of a goods holder stored in a storage cell according to claim <NUM>. For the sake of brevity, advantages discussed above in connection with the first to third aspects of the invention may even be attributed to the method and are not further discussed.

For the purposes of this application, the term "container handling vehicle" used in "Background and Prior Art"-section of the application and the term "remotely operated vehicle" used in "Summary of the Invention"- and Detailed Description of the Invention"-sections both define a robotic wheeled vehicle operating on a rail system arranged across the top of the framework structure being part of an automated storage and retrieval system.

Analogously, the term "storage container" used in "Background and Prior Art"-section of the application and the term "goods holder" used in "Detailed Description of the Invention"-section both define a receptacle for storing items. In this context, the goods holder can be a bin, a tote, a pallet, a tray or similar. Different types of goods holders may be used in the same automated storage and retrieval system. The relative terms "upper", "lower", "below", "above", "higher" etc. shall be understood in their normal sense and as seen in a Cartesian coordinate system. When mentioned in relation to a rail system, "upper" or "above" shall be understood as a position closer to the surface rail system (relative to another component), contrary to the terms "lower" or "below" which shall be understood as a position further away from the rail system (relative another component).

The framework structure <NUM> of the automated storage and retrieval system <NUM> is constructed in accordance with the prior art framework structure <NUM> described above in connection with <FIG>, i.e. a number of upright members <NUM>, wherein the framework structure <NUM> also comprises a first, upper rail system <NUM> in the X direction and Y direction.

The framework structure <NUM> further comprises storage compartments in the form of storage columns <NUM> provided between the members <NUM> where storage containers <NUM> are stackable in stacks <NUM> within the storage columns <NUM>.

In particular, it is understood that the framework structure can be considerably wider and/or longer and/or deeper than disclosed in <FIG>.

<FIG> is a perspective view of a storage and pick-up module <NUM>. The module <NUM> comprises a plurality of assemblies <NUM>. Each assembly <NUM> comprises a goods holder <NUM> stored in a storage cell <NUM>. The goods holders <NUM> are arranged in stacks so that these stacks extend vertically along a storage column <NUM> of the module <NUM>. A remotely operated vehicle <NUM> for handling goods holders <NUM> is also shown. The vehicle <NUM> moves along the rails having the same function as the rails discussed in connection with <FIG>. Normally, the module <NUM> is coupled to a framework structure of an automated storage and retrieval system shown in <FIG>. Still with reference to <FIG>, such a system typically comprises a storage grid and a rail system arranged across the top of the automated storage and retrieval system. The goods holders <NUM> may be bidirectionally transferred between the storage grid and the storage cells <NUM> of the module <NUM>. This transfer is carried out by the remotely operated vehicle <NUM>.

Hereby, a simple solution for quickly replenishing the module <NUM> is achieved. More specifically, the remotely operated vehicles <NUM> operating on the rail system have access from above to the system as well as to the module <NUM>. If a transfer of goods holder(s) <NUM>, either from the module <NUM> to the rest of the system, or in the opposite direction, is required, the highly efficient, system-native remotely operated vehicles <NUM> are employed.

In the related context, the use of module <NUM> obviates the need for a dedicated product-staging area - the purchased products are immediately stored in a module <NUM> placed in an area that serves as a combined staging area and pick-up area. Hereby, customer waiting times are significantly reduced because once the goods holder is in the storage cell <NUM> of the module <NUM>, it is immediately available for pickup. Also, by virtue of the module, all goods holders <NUM> are at all times accessible for customers such that high pick-up throughput may be achieved.

Typically, the module <NUM> is detachable and suitable for coupling, e.g. slotting, to a framework structure of an automated storage and retrieval system shown in <FIG>. By way of example, coupling of the module <NUM> to the automated storage and retrieval system may be effectuated by means of a forklift (not shown). As an alternative, the module <NUM> may be provided with wheels (not shown) so as to enable manual handling. Regardless of the method used, it is necessary to properly align the module with the system. This may be achieved in various ways well known to the person skilled in the art. By way of example, a detached module may advantageously be positioned outside of the warehouse in order to provide <NUM>/<NUM> access.

<FIG> is a perspective view of the module <NUM> of <FIG> further showing a two-dimensional, vertically extending protective structure <NUM>. The protective structure <NUM> covers front side of the goods holders stored in storage cells. The main purpose of the protective structure is to ensure customer safety in situations involving moving parts. More specifically, customers are prevented from inserting their hands into an empty storage cell while said cell is receiving the goods holder (introduced by the robot <NUM>). The protective structure <NUM> may have different shapes and sizes. For the sake of brevity, the parts discussed above in connection with <FIG> are not further discussed in connection with <FIG>.

<FIG> shows a goods holder <NUM> of the present invention in closed state. The goods holder <NUM> comprises a front side <NUM>. A section <NUM> of the front side <NUM> is movable, preferably pivotable, so as to allow access into the interior of the goods holder <NUM>. An inlet <NUM> of a through-hole arranged in a first lateral side <NUM> of the goods holder <NUM> may also be seen. Further, recesses <NUM>, for receiving gripper elements shown in connection with <FIG>, are arranged in a body of the goods holder <NUM>. With reference to <FIG>, it is necessary to ensure that the movable section <NUM> is closed, i.e. in the state shown in <FIG>, prior to the goods holder being transferred between the storage grid and the storage cells of the module.

In one embodiment, goods holders <NUM> are made in polymer material and share a lot of structural properties with the traditional goods holders for use in the system of <FIG>. In the context, goods holders <NUM> have the same size as the traditional goods holders. In another embodiment, the polymer goods holders have thicker walls and/or are structurally reinforced, alternatively made in metal such as steel.

<FIG> shows a goods holder <NUM> of the present invention in open state. The movable section <NUM> comprises a horizontally extending blind hole <NUM> for receiving a bolt of a locking mechanism discussed in connection with <FIG>. A horizontally extending through-hole <NUM> for receiving said bolt is arranged in a first lateral side <NUM> of the goods holder. The through-hole <NUM> becomes aligned with the blind hole <NUM> of the movable section <NUM> when the movable section <NUM> is secured. In the shown embodiment, the movable section <NUM> is a door hinged along an edge <NUM> of the goods holder <NUM>, said edge <NUM> being associated with a second lateral side <NUM> of the goods holder. The second lateral side <NUM> is arranged opposite the first lateral side <NUM>. For the sake of brevity, the parts discussed above in connection with <FIG> are not further discussed in connection with <FIG>.

<FIG> shows details of a storage cell <NUM> for storing the goods holder <NUM>. The storage cell <NUM> and the goods holder <NUM>, tightly fit into said cell, make up an assembly <NUM>. The storage cell <NUM> is provided with a locking mechanism <NUM> configured to engage with the movable section of the front side (shown in <FIG>) of the stored goods holder <NUM> so as to secure said movable section. The storage cell <NUM> is laterally delimited by portions of vertically extending upright members <NUM>' and the locking mechanism <NUM> is attached to the one, vertically extending upright member <NUM>'.

The storage cell <NUM> is also provided with a sensor <NUM> for detecting position of the movable section of the front side. The locking mechanism <NUM> comprises a movable bolt <NUM> and an actuator <NUM> which activates the bolt <NUM> so that said bolt engages with the movable section of the front side provided that the sensor <NUM> determines that the section is in the correct position. For the sake of clarity, the movable bolt <NUM> is shown in activated state in <FIG>. The storage cell <NUM> further comprises a control unit <NUM> for controlling operation of the actuator <NUM>. A cable <NUM> carries control signals from the control unit <NUM> to the actuator <NUM> of the locking mechanism <NUM>. Power required for movement of the bolt is supplied via power cable <NUM> (power source is not shown in <FIG>).

Hereby, a fully automated solution, i.e. a solution that doesn't require attendance by an operator for product delivery, is obtained. More specifically and with reference to <FIG>, container handling vehicles stack goods holders filled with purchased products into storage cells of the module in a usual manner whereby locking mechanism associated with each storage cell is activated. The storage cells containing goods holders are located in an area accessible by customers - a so-called pick-up area. Thus, a customer desiring to collect purchased products only needs to access the pick-up area and deactivate the locking mechanism <NUM> in order to gain access to the interior of the goods holder and complete the pick-up. The deactivation is normally triggered by the customer using a suitable human-machine-interface in order to provide instructions to the control unit <NUM> controlling the locking mechanism <NUM> associated with the storage cell <NUM>. Such an interface could be a terminal located on a front side of the module of <FIG>. As an alternative, the interaction between the customer and the control unit <NUM> is based on wireless communication and is initiated by the customer providing instructions via his/hers smart phone.

To ensure proper alignment of the bolt <NUM> and the through-hole of <FIG>, the storage cell <NUM> could comprise a detector (not shown) for determining position of the goods holder when stored in the storage cell.

Claim 1:
An assembly (<NUM>) comprising:
- a goods holder (<NUM>) comprising a front side (<NUM>), wherein at least a section (<NUM>) of the front side (<NUM>) is movable so as to allow access into the interior of the goods holder (<NUM>),
- a storage cell (<NUM>) for storing the goods holder (<NUM>),
- said storage cell (<NUM>) being provided with a locking mechanism (<NUM>) configured to engage with the movable section (<NUM>) of the front side (<NUM>) of the stored goods holder (<NUM>) so as to secure said movable section (<NUM>), characterized in that
- said assembly (<NUM>) is configured such that the goods holder (<NUM>) stored in the storage cell (<NUM>) is accessible from above by means of a remotely operated vehicle (<NUM>) operating on a rail system (<NUM>).