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

The framework structure <NUM> comprises several upright members <NUM> and several 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 <NUM> defines a storage grid <NUM> comprising storage columns <NUM> arranged in rows, in which storage columns <NUM> storage containers <NUM>, also known as bins, are stacked one on top of another to form stacks <NUM>. The storage grid <NUM> 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.

The automated storage and retrieval system <NUM> comprises a rail system <NUM> arranged in a grid pattern across the top of the storage <NUM>, on which rail system <NUM> a plurality of container handling vehicles <NUM>, <NUM> are operated to raise storage containers <NUM> from, and lower storage containers <NUM> into, the storage columns <NUM>, and 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. In this way, the rail system <NUM> defines grid columns <NUM> above which 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> comprises a vehicle body 201a, 301a, and first and second sets of wheels 201b, 301b, 201c, 301c which enable the lateral movement of the container handling vehicles <NUM>, <NUM> in the X direction and in the Y direction, respectively. The first set of wheels 201b, 301b is arranged to engage with two adjacent rails of the first set <NUM> of rails, and the second set of wheels 201c, 301c is arranged to engage with two adjacent rails of the second set <NUM> of rails. Each set of wheels 201b, 301b, 201c, 301c can be lifted and lowered, so that the first set of wheels 201b, 301b and/or the second set of wheels 201c, 301c can be engaged with the respective set of rails <NUM>, <NUM> at any one time.

Each prior art container handling vehicle <NUM>, <NUM> also comprises a lifting device (not shown) 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 comprises one or more gripping / engaging devices (not shown) which are adapted to engage a storage container <NUM>, and which gripping / engaging devices can be lowered from the vehicle <NUM>, <NUM> so that the position of the gripping / engaging devices with respect to the vehicle <NUM>, <NUM> can be adjusted in a third direction Z which is orthogonal the first direction X and the second direction Y.

Each prior art container handling vehicle <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 central 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 grid column <NUM>, i.e. the extent of a grid column <NUM> in the X and Y directions, e.g. as is described in <CIT>.

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

Alternatively, the central cavity container handling vehicles <NUM> may have a footprint which is larger than the lateral area defined by a grid column <NUM>, e.g. as is disclosed in <CIT>.

In the X and Y directions, neighbouring grid cells are arranged in contact with each other such that there is no space there-between.

In a storage grid <NUM>, most of the grid columns <NUM> are storage columns <NUM>, i.e. grid columns <NUM> where storage containers <NUM> are stored in stacks <NUM>. However, a grid <NUM> normally has at least one grid column <NUM> which is used not for storing storage containers <NUM>, but which comprises a location where the container handling vehicles <NUM>, <NUM> can 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 grid <NUM> or transferred out of or into the grid <NUM>. Within the art, such a location is normally referred to as a 'port' and the grid column <NUM> in which the port is located may be referred to as a 'port column' <NUM>, <NUM>. For example, the storage containers <NUM> may be placed in a random or dedicated grid column <NUM> within the storage grid <NUM>, then picked up by any container handling vehicle and transported to a port <NUM>, <NUM> for further transportation to an access station.

When a storage container <NUM> stored in the grid <NUM> disclosed in <FIG> is to be accessed, one of the container handling vehicles <NUM>, <NUM> is instructed to retrieve the target storage container <NUM> 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>, <NUM> to a grid 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> lifting devices (not shown), and transporting the storage container <NUM> to the drop-off port <NUM>. If the target storage container <NUM> is located deep within a stack <NUM>, i.e. with one or a plurality of other storage containers <NUM> positioned above the target storage container <NUM>, the operation also involves temporarily moving the above-positioned storage containers <NUM> prior to lifting the target storage container <NUM> from the storage column <NUM>. This step, which is sometimes referred to as "digging" within the art, may be performed with the same container handling vehicle that is subsequently used for transporting the target storage container <NUM> to the drop-off port <NUM>, or with one or a plurality of other cooperating container handling vehicles. Alternatively, or in addition, the automated storage and retrieval system <NUM> may have container handling vehicles 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.

When a storage container <NUM> is to be stored in the grid <NUM>, one of the container handling vehicles <NUM>, <NUM> is instructed to pick up the storage container <NUM> from the pick-up port <NUM> and transport it to a grid location above the storage column <NUM> where it is to be stored. After any storage containers <NUM> positioned at or above the target position within the storage column stack <NUM> have been removed, the container handling vehicle <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.

<FIG> describes a delivery vehicle. The delivery vehicles comprise a base with the same setup of wheels as on the container handling vehicles. The wheel base unit the connected set of wheels relative to the other set of wheels such that only the set of wheels travelling in a desired direction is in contact with the rail grid. The wheel displacement assembly is driven by an electric motor. Further, two electric motors, powered by a rechargeable battery, are connected to the set of wheels to move the wheel base unit in the desired direction. The horizontal periphery of the wheel base unit is dimensioned to fit within the horizontal area defined by a grid cell of the rail grid such that two-wheel base units may pass each other on any adjacent grid cells of the rail grid. In other words, the wheel base unit may have a footprint, i.e. an extent in the X and Y directions, which is generally equal to the horizontal area of a grid cell, i.e. the extent of a grid cell in the X and Y directions, e.g. as is described in <CIT>.

A problem with the prior art solutions is that if there are perishable items in the storage there is a need for measuring the freshness of the products and the conditions the items are stored in. There is however a problem with getting accurate readings of the items without having to turn to costly solutions that require expensive equipment or extensive rebuilds. It is therefore an object of the present invention to solve these problems.

<CIT>, which the EPO identified in the examination procedure as the 'closest prior art', describes, according to its abstract, a storage system where goods are stored in containers and the containers are stored in stacks. Above the stacks runs a grid network of tracks on which load handling devices run to lift containers from the stacks and deposit them at alternative locations in the stacks or at stations where goods may be removed or alternative functions may be undertaken. The containers can provide the following exemplary services: power, power control, heating, lighting, cooling, sensing, and data logging. The provision of these services within individual containers rather than across the system as a whole, allows for flexibility in storage whilst reducing cost and inefficiency. The containers when removed from the stacks are electrically connected to the load handling device, power being supplied by a power supply within the load handling device.

In a first aspect of the invention, an automated storage and retrieval system according to claim <NUM> is provided.

The measuring equipment can be a temperature sensor, moisture sensor and/or at least one gas detector. Also, the box-shaped measuring unit has measuring equipment on all sides of the box-shaped measuring unit. Further, different equipment may be placed on different sides of the box-shaped measuring unit.

The measuring system wherein the box-shaped measuring units can have an RFID reader on one side.

Further, the box-shaped measuring unit can be provided with a removable lid for giving access to the measuring equipment inside the box-shaped measuring unit. The main rechargeable power source of the box-shaped measuring unit can be placed in the lid of the box-shaped measuring unit. In order to hold the lid in place on the box of the box-shaped measuring unit, the lid can be supplied with a set of grippers, gripping the box of the box-shaped measuring unit. These grippers can be remotely controlled by the central computer system.

Further the at least one rechargeable power source of the measuring system can be charged via an interface to the lifting frame of the container handling vehicle.

In an alternative solution the measuring system can have a back-up rechargeable power source placed inside the box-shaped measuring unit. This back-up power supply can be adapted to provide power to the measuring equipment inside the box-shaped measurement unit when the lid is off.

In an alternative solution there are placed a plurality of box-shaped measuring units in the storage system and the box-shaped measuring units can communicate with other box-shaped measuring units within the same automated storage system.

In a second aspect of the invention, a method for monitoring atmospheric conditions according to claim <NUM> is provided.

Further it is possible to charge the at least one rechargeable power source of the box-shaped measuring unit via the lifting frame of the container handling vehicle. In this solution the rechargeable power supply of the container handling vehicle is used to top up the rechargeable power supply of the box-shaped measuring unit. Further a set of grippers of the lid of the box-shaped measuring unit can be remotely controlled by the central computer system.

Also, the back-up power supply can direct power to the measuring equipment connected to the box-shaped measuring unit if the lid is off.

In an alternative solution the measurement data collected by the measuring equipment can be transferred from the box-shaped measuring unit to the container handling vehicle when said vehicle is handling the box-shaped measuring unit.

The following drawings are appended to facilitate the understanding of the invention.

<FIG> is an alternative solution of a container handling vehicle <NUM> with a central cavity solution.

<FIG> describes a delivery vehicle. The delivery vehicles comprise a base with the same setup of wheels as on the container handling vehicles. The wheel base unit features a wheel arrangement having a first set of wheels for movement in a first direction upon a rail grid (i.e. any of the top rail grid and the transfer rail grid) and a second set of wheels for movement in a second direction perpendicular to the first direction. Each set of wheels comprises two pairs of wheels arranged on opposite sides of the wheel base unit. To change the direction in which the wheel base unit may travel upon the rail grid, one of the sets of wheels is connected to a wheel displacement assembly. The wheel displacement assembly is able to lift and lower the connected set of wheels relative to the other set of wheels such that only the set of wheels travelling in a desired direction is in contact with the rail grid. The wheel displacement assembly is driven by an electric motor. Further, two electric motors, powered by a rechargeable battery, are connected to the set of wheels to move the wheel base unit in the desired direction. The horizontal periphery of the wheel base unit is dimensioned to fit within the horizontal area defined by a grid cell of the rail grid such that two-wheel base units may pass each other on any adjacent grid cells of the rail grid. In other words, the wheel base unit may have a footprint, i.e. an extent in the X and Y directions, which is generally equal to the horizontal area of a grid cell, i.e. the extent of a grid cell in the X and Y directions.

One embodiment of the automated storage and retrieval system according to the invention will now be discussed in more detail with reference to <FIG>.

<FIG> are side views of a storage system with storage containers wherein a container handling vehicle transports a box-shaped measuring unit <NUM> into the storage system, places it at a predetermined position within the storage system and leaves. The predetermined position is where the box-shaped measuring unit <NUM> can have the most effect in detecting anomalies within the storage system. The position can be either at a certain level of the storage system (for example, towards the top or upper part of the storage system, or towards the bottom or lower part of the storage system) and/or at a certain distance from other box-shaped measuring units <NUM> in the storage system (for example, in order to triangulate a location of a problem within the storage system).

Further the position can be in order to detect specific atmospheric conditions like specific gasses. Since some of the gasses produced by decomposing or rotting food items are lighter than air and some gasses are heavier than air it is essential where the box-shaped measuring units <NUM> are placed in order to detect decomposing matter. One gas produced by rotting food is methane. Methane is lighter than air and will therefore move upwards. A sensor for measuring methane should therefore be placed as high up in the storage system as possible. Other gasses that are released during the rotting of food are carbon dioxide and hydrogen sulphide. In these cases, the gasses are heavier than air and will collect at the bottom, so sensors for detecting carbon dioxide and hydrogen sulphide should therefore be placed as low to the ground as possible.

Further, since cold air is heavier than warm air there is a benefit of placing a box-shaped measuring unit <NUM> either high up in the stack of container or low down depending on what you want to detect. If e.g. the intention is to ensure that the storage facility does not get too warm it is essential that the box-shaped measuring unit <NUM> is placed where the air is the hottest, i.e. the top of the stack of containers. If, however the intention is to ensure that the storage facility does not get too cold the box-shaped measuring unit <NUM> needs to be placed at the bottom of the stack of containers. If there is a need to ensure that the storage facility is within a certain temperature span, there can be placed one box-shaped measuring unit <NUM> on the top of the stack of containers and one box-shaped measuring unit <NUM> at the bottom of the stack of containers. Further it is possible to decide the position based on the proximity to other box-shaped measuring units <NUM>, in order to better be able to pinpoint where there is a problem, or to ensure that the box-shaped measuring units <NUM> can communicate with each other using a short-range radio network like e.g. Bluetooth.

The box shaped measuring unit <NUM> comprises measuring equipment. This measuring equipment might be temperature sensors, moistures sensors, gas detectors or any other type of sensors for measuring atmospheric conditions around the box-shaped measuring unit <NUM>. The detectors can detect evidence of decomposing of perishable items or if there are problems with the atmospheric conditions the items are stored in. Sensors can be placed on one or more sides of the box-shaped measuring unit <NUM>. In a preferred embodiment there can be sensors placed on each side of the box-shaped measuring unit <NUM>. This enables it to detect on which side of the box-shaped measuring unit <NUM> there are signs of problems with either the atmospheric conditions of the storage system or the items stored in the containers. If there are more than one container stored in the storage system, the result from the separate box-shaped measuring units <NUM> can be used in order to pinpoint where in the grid there is a problem. If two or more box-shaped measuring units <NUM> can detect on which side of the box e.g. a specific gas is present the central computer system can decide that there is a problem somewhere between these two or more boxes.

The box-shaped measuring unit <NUM> comprises in addition to the measuring equipment at least one rechargeable power source and at least one form of communication equipment.

In an alternative solution the box-shaped measuring unit <NUM> is comprised of a top and a bottom part. The top part acts as a lid to the bottom part. Together the size of the top and bottom part may be of the same size as an ordinary storage container in the storage system. The top part can function as a lid keeping the equipment inside the box safe. Further, the lid can comprise a rechargeable power source that gives power to the equipment in the box-shaped measuring unit <NUM>.

By having a rechargeable power source in the lid of the box-shaped measuring unit <NUM> it is possible to change the power source without having to remove the box-shaped measuring unit <NUM> from the storage facility. The bottom part of the box-shaped measuring unit <NUM> can have an auxiliary rechargeable power source that helps to maintain the operation of the box-shaped measuring unit <NUM> until there is a new lid placed on the bottom part of the box-shaped measuring unit <NUM>. The top and the bottom part of the box-shaped measuring unit <NUM> can be held together by a second set of grippers. The second set of grippers makes it possible to lift the top and the bottom part of the box-shaped measuring unit <NUM> by only connecting a first set of grippers to the top part. The second set of grippers are placed in the top part of the box-shaped measuring unit <NUM> and they are the same as the first set of grippers on the lifting platform of the container handling vehicles. This ensures that both the top and the bottom part of the box-shaped measuring unit <NUM> can be lifted by ordinary container handling vehicles without having to add additional equipment for handling the box-shaped measuring unit <NUM> to the container handling vehicles.

<FIG> is a flowchart describing the steps in the process of a preferred embodiment of the present invention. The container handling vehicle places a box-shaped measuring unit <NUM> in the storage grid. After the box-shaped measuring unit <NUM> has been placed in the storage grid it starts to gather information (measurement data) from the measuring equipment placed in the box-shaped measuring unit <NUM>. If the box-shaped measuring unit <NUM> is connected to a network, like Wi-Fi, the gathered information is sent to a computer system. This computer system can be just for keeping track of the measurements of the box-shaped measuring units <NUM> and analyze the results. And based on the results it can instruct the central computer system to perform certain actions like searching for containers with a potential problem with its items in a certain area of the storage system, or alarming about a rise or fall in temperature.

If the box-shaped measuring unit <NUM> is not connected to a network the data can be stored in a data recorder within the box-shaped measuring unit <NUM> and transmitted to the central computer system when the box-shaped measuring unit <NUM> is connected to the network again. If the box-shaped measuring unit <NUM> is not connected to a network for longer than a predetermined period of time the data can be uploaded to the computer system when a container handling vehicle is handling the box-shaped measuring unit <NUM> when the lifting platform of a container handling vehicle is attached to the box-shaped measuring unit <NUM>, the stored measurement data from the measuring equipment can be transmitted to the container handling vehicle, which again can send it to the computer system. The lifting platform of a container handling vehicle can have an interface that connects with the box-shaped measuring unit <NUM> and hence enables transfer. A reason for the box-shaped measuring unit <NUM> being disconnected from the network can be that the transmitter or the communication equipment in the box-shaped measuring unit <NUM> is broken. If this is the case the container handling vehicle can transport the box-shaped measuring unit <NUM> to a service station for repair. Further the box-shaped measuring unit <NUM> comprises at least one rechargeable power source. The rechargeable power sources can be batteries or a battery and a capacitor.

When the charge of the power source(s) get low a message is sent to the central computer system that the battery needs to be charged. The central computer system orders a container handling vehicle to pick up the box-shaped measuring unit <NUM> and transport it to a charger. When finished it is transported back into the storage system.

If the box-shaped measuring unit <NUM> is made up of a top and a bottom part the top part is transported to the charger and a new top part with a fully charged rechargeable power source is placed on the bottom part of the box-shaped measuring unit <NUM>. In this solution the box-shaped measuring unit <NUM> does not need to be transported away from its position in the storage facility and it can hence keep measuring and transmitting data continuously. If the box-shaped measuring unit is to be moved to another place in the storage facility the at least one rechargeable power source can be topped up via the lifting platform of the container handling vehicle.

The box-shaped measuring unit <NUM> has measuring equipment on all sides. This allows for keeping track of changes in the atmospheric conditions on all sides of the box-shaped measuring unit <NUM>. Further it is possible to better pinpoint where in the storage system there is detected evidence of items going spoiled. If there are more than one box-shaped measuring unit <NUM> in the storage system, the combined result from all the box-shaped measuring units <NUM> can make it possible to detect spoiling items before they are able to spoil other items in the storage system.

One solution for keeping track of the changes in atmospheric conditions in the storage system is to record the measurement data from the measuring equipment together with timestamps and transmit the recorded measurement data to a computer system. The time stamp makes it possible to keep track of the development of the measurement data over time. In order to be able to locate where in the storage system there is a problem, the ID of the sensor or the measuring equipment can also be logged. The ID of the sensor or measuring equipment makes it possible to decide which box-shaped measuring unit <NUM> it is and since the system always knows where in the system any box-shaped measuring unit <NUM> is, the location of the spoiled item is possible. Also, if there are more than one box-shaped measuring unit <NUM> the combined results of the measurements from all the separate box-shaped measuring units <NUM> together with the time stamps allows the computer system to pinpoint where in the system there is a problem.

However, to get as accurate a measurement as possible, it is important that the system knows which way the box-shaped measuring unit <NUM> is oriented in the storage grid. The ID of the sensor only gives the information that there is a problem close to that sensor, it tells nothing about which way the sensor is pointing. However, there are several ways that can be used to find out which way the box-shaped measuring unit <NUM> is facing.

One way is to monitor which way the box-shaped measuring unit enters the storage system. Since the container handling vehicles can only move in two directions and since they cannot turn, the direction of the box-shaped measuring unit <NUM> will not change as long as it is in the storage grid. However, if the box-shaped measuring unit <NUM> is transported out of the storage system, like when it is charged, or it is in the service station for repair, the direction of the box-shaped measuring unit <NUM> can change and the direction the box-shaped measuring unit <NUM> enters the storage system must be noted and fed into the computer system again.

Another way of knowing which way the box-shaped measuring unit <NUM> is facing is to have a form of ID marker at one end of the storage system. The box-shaped measuring unit <NUM> has a reader on one side and it can detect the marker if it is facing towards the marker, if the box-shaped measuring unit <NUM> is not able to detect the marker, is it facing the other way. Since the containers and the box-shaped measuring units <NUM> are rectangular they can only be stored in two directions. The ID marker can be in the form of the box-shaped measuring unit <NUM> can communicate with e.g. an RFID mark placed on a specific place in the storage system. The box-shaped measuring unit <NUM> can have an RF reader on one side and regardless if it gets a result or not, the direction of the box-shaped measuring unit <NUM> can be determined since if it gets a result, the box-shaped measuring unit <NUM> is facing one way and if it does not get a result, it is facing the other way.

Alternatively, if there are box-shaped measuring units <NUM> at regular intervals in the storage system. It is possible to detect where there is a problem if sensors in more than one box-shaped measuring unit <NUM> gives a result. If more than one box gives a result it is not necessary to know the direction of the box-shaped measuring units <NUM> since it is safe to say that if two box-shaped measuring units <NUM> placed close together gets a reading the problem item is somewhere between the two or more units.

Claim 1:
An automated storage and retrieval system comprising a framework structure (<NUM>) forming a three-dimensional storage grid structure (<NUM>) for storing storage containers (<NUM>) for storing items, where the grid structure (<NUM>) forms vertical storage columns (<NUM>) each having a horizontal area defined by the size of an access opening (<NUM>) of the vertical storage columns (<NUM>) and where a rail system (<NUM>) is arranged on the framework structure (<NUM>) defining the circumference of each access opening (<NUM>) on top of each storage column (<NUM>), the rail system (<NUM>) providing available routes for container handling vehicles (<NUM>) handling and transferring the storage containers (<NUM>) to and from the storage columns (<NUM>), and the at least one container handling vehicle (<NUM>, <NUM>) has at least one rechargeable power source (<NUM>), and a container handling platform (<NUM>) with a first set of grippers for handling the storage containers (<NUM>), and a measuring system for monitoring atmospheric conditions in the automated storage and retrieval system comprising at least one box-shaped measuring unit (<NUM>) of the same size and features as a storage container (<NUM>) for being stored in the three-dimensional storage grid structure by being placed by the at least one container handling vehicle, and where the box-shaped measuring unit (<NUM>) comprises measuring equipment for measuring at least one atmospheric condition within the grid structure, a transmitter for transmitting measurement data to a computer system, at least one rechargeable power source and a data recorder for recording the measurement data characterized in that the box-shaped measuring unit (<NUM>) comprises measuring equipment on all sides of the box-shaped measuring unit (<NUM>).