Patent Description:
<CIT> which the EPO identified in the examination procedure as the 'closest prior art', describes a storage system for automatic delivery of one or more items stored in compartments of a storage container, and a station for such a storage system. The framework of the storage system is constructed to comprise a plurality of upright members and a plurality of horizontal members which are supported by the upright members, wherein the horizontal members include a container handling vehicle rail system of parallel rails in the X direction and the Y direction, respectively, arranged across the top of storage columns. A section of a storage grid comprises a picking and/or supply station comprising an access barrier in the form of a drawer-like device. The drawer-like device, in a loading configuration, is completely contained in a housing. The housing is able to prevent access to the opening of the access barrier. The access barrier is adapted to receive a storage container comprising at least one storage compartment for temporarily storing a product/item to be picked from or supplied to the storage grid. The access barrier comprises an opening, and a plurality of covers, wherein each cover is arranged to be selectively deployed to close off a respective portion of the opening, and thereby restrict access therethrough.

<CIT> describes an automated storage and retrieval system comprising a three-dimensional grid and multiple container handling vehicles, wherein the three-dimensional grid comprises multiple storage columns, in which containers are stored one on top of another in vertical stacks, and multiple port columns through which the containers can be transferred between the top level of the grid and a container handling station; and the container handling vehicles are operated on a top level of the grid for retrieving containers from, and storing containers in, the storage columns, and for transporting the containers horizontally across the grid to or from the multiple port columns; wherein the container handling station comprises a horizontal container carousel comprising a first straight conveyor section and a second straight conveyor section interconnected by two intermediate conveyor sections, each of the conveyor sections comprises at least one conveyor device for accommodating and moving a container in a horizontal direction; the first straight conveyor section is arranged directly below the multiple port columns, such that any of the container handling vehicles may transfer a container between the top level of the grid and the first straight conveyor section via any of the multiple port columns; and the second straight conveyor section is arranged to allow access to a container retrieved from the grid via the first straight conveyor section.

<FIG> discloses a prior art automated storage and retrieval system <NUM> with a framework structure <NUM> and <FIG> and <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>. 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>,<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>,<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>,<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>,<NUM> through access openings <NUM> in the rail system <NUM>. The container handling vehicles <NUM>,<NUM>,<NUM> can move laterally above the storage columns <NUM>, i.e. in a plane which is parallel to the horizontal X-Y plane.

The stacks <NUM> of containers <NUM> are typically self-supporting.

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 the lateral movement of the container handling vehicles <NUM>,<NUM>,<NUM> in the X direction and in the Y direction, respectively. In <FIG> and <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 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 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 which is orthogonal to 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 <NUM>,<NUM>. The gripping device of the container handling device <NUM> is located within the vehicle body 201a in <FIG> and is thus not shown.

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,401a as shown in <FIG> and <FIG> and as described in e.g. <CIT> and <CIT>.

Such a vehicle is described in detail in e.g. NO3173 <NUM>.

The cavity container handling vehicle <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 <FIG>, e.g. as is disclosed in <CIT> or <CIT>. Each rail may comprise one track, or each rail <NUM>,<NUM> may comprise two parallel tracks. In other rail systems <NUM>, each rail in one direction (e.g. an X direction) may comprise one track and each rail in the other, perpendicular direction (e.g. a Y direction) may comprise two tracks. Each rail <NUM>,<NUM> may also comprise two track members that are fastened together, each track member providing one of a pair of tracks provided by each rail.

<CIT>, illustrates a typical configuration of rail system <NUM> comprising rails and parallel tracks in both X and Y directions
In the framework structure <NUM>, a majority of the columns <NUM> are storage columns <NUM>, i.e. columns <NUM> where storage containers <NUM> are stored in stacks <NUM>. 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 ontside of the framework structure <NUM> or transferred out of or into the framework structure <NUM>. The transportation to the access station may be in any direction that is horizontal, tilted and/or vertical. 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>,<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 returned into the framework structure <NUM> again once accessed. 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.

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>,<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 any 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> which typically is computerized and which typically comprises a database for keeping track of the storage containers <NUM>.

An access station for picking storage containers is disclosed in <CIT>. This access station comprises an entry conveyor and an exit conveyor. Given the presence of both an entry and exit conveyor, the access station therefore has a footprint exceeding the width/length of a storage column. As such, where two access stations are situated adjacent to one another, there will therefore be some distance between the picking zone of two adjacent access stations.

The access station disclosed in <CIT> also has many moving or rotating components, particularly associated with the conveyors, that are prone to wear and regularly require maintenance.

An objective of the present invention is therefore to provide a more compact access station where picking zones of adjacent access stations can be arranged closer to each other.

A further objective of the present invention is to reduce the complexity of the access station, particularly regarding the number of moving components.

The present invention relates to an automated storage and retrieval system according to claim <NUM> and an access station according to claim <NUM>. Further embodiments of the automated storage and retrieval system are defined in dependent claims <NUM> to <NUM>.

An example automated storage and retrieval system useful for understanding the invention to which this European patent relates comprises a framework structure, wherein the framework structure comprises:.

In one example useful for understanding the invention to which this European patent relates, the framework structure comprises outer panels secured between at least some of the peripherical upright members and wherein the access station is insertable into and retrievable out from the access station compartment via a side opening in one of the panels.

An example automated storage and retrieval system useful for understanding the invention to which this European patent relates is according any one of the above examples, wherein the access station compartment has a width being larger than a distance between two upright members, wherein the width is measured in a direction coinciding with or in a direction parallel with the distance.

In one example useful for understanding the invention to which this European patent relates, the width and the distance are measured perpendicular to the direction of horizontal movement of the storage container in the access station.

In one example useful for understanding the invention to which this European patent relates , the framework structure comprises a receptacle frame defining the access station compartment, wherein the receptacle frame is forming a support for a plurality of upright members.

In one example useful for understanding the invention to which this European patent relates, the receptacle frame comprises upright frame members and cross-members connected between the upright frame members.

In one example useful for understanding the invention to which this European patent relates, the width of the access station compartment is measured as the distance between two upright frame members.

In one example useful for understanding the invention to which this European patent relates, the access station compartment is located in the periphery of the framework structure.

In one example useful for understanding the invention to which this European patent relates, the access station is situated in the access station compartment during operation of the access station.

In one example useful for understanding the invention to which this European patent relates, the access station is situated outside of the access station compartment during maintenance, repair and/or service of the access station.

In one example useful for understanding the invention to which this European patent relates, the access station is forming one single modular unit. Alternatively, the access station is forming a few modular units. Hence, the operation of inserting the access station into the access station compartment and the operation of retrieving the access station from the access station compartment can be relatively efficient.

In one example useful for understanding the invention to which this European patent relates, the access station comprises an access module comprising a frame, wherein the access station comprises wheels secured to the frame for rolling the access station into and out from the access station compartment via the side opening.

In one example useful for understanding the invention to which this European patent relates, the access station comprises two, three or four wheels. In one example useful for understanding the invention to which this European patent relates, the wheels are in the form of rollers. In one example useful for understanding the invention to which this European patent relates, the wheels are castor wheels, e.g., each provided at a lower end of a vertically extending mount. The castor wheels may be a rigid type of castor wheel or a swivel type of castor wheel.

In one example useful for understanding the invention to which this European patent relates, the framework structure comprises a support plate situated within the access station compartment and secured between a plurality of the upright members, wherein the wheels of the access station are supported on the support plate when inserted into the access station compartment.

In one example useful for understanding the invention to which this European patent relates, the support plate may ensure, or at least contribute to, a correct alignment of the access station within the access station compartment.

In one example useful for understanding the invention to which this European patent relates, the access station comprises:.

wherein the conveyor module is insertable into and retrievable out from the access station compartment.

According to the above, the access station comprises three modules.

In one example useful for understanding the invention to which this European patent relates, the main module is surrounding the side opening. Hence, the only way to access a storage container received within the main module is through the top cover. In one example useful for understanding the invention to which this European patent relates, the main module is secured to the panel and/or to upright members of the framework structure. In one example useful for understanding the invention to which this European patent relates, the main module is a wall hanging module. Alternatively, the main module is a floor standing module comprising for example legs or another type of base structure. In one example useful for understanding the invention to which this European patent relates, the main module is a furniture-like structure, such as a cabinet.

In one example useful for understanding the invention to which this European patent relates, the access station comprises a top opening alignable below one of the columns when the access station is inserted into the access station compartment, wherein at least one of the container handling vehicles is configured to supply a storage container to the access station through the column and/or to retrieve a storage container from the access station through the column when the access station is inserted into the access station compartment and aligned with the column.

In one example useful for understanding the invention to which this European patent relates, the framework structure comprises horizontal members connected between the upright members at a height that permits the access station to be inserted into the access station compartment underneath the horizontal members.

In one example useful for understanding the invention to which this European patent relates, the access station comprises a jack for elevating an upper portion of the access station upwardly within the access station compartment.

In one example useful for understanding the invention to which this European patent relates, access station compartment comprises a roof portion. The roof portion may be formed by downwardly facing surfaces of the horizontal members. In one example useful for understanding the invention to which this European patent relates, the top opening is located between horizontal members. The jack may be configured to elevate the access station up towards the roof portion within the access station compartment once inserted therein.

In one example useful for understanding the invention to which this European patent relates, the frame is defining a drawer compartment provided within the frame;.

In one example useful for understanding the invention to which this European patent relates, the access station comprises a front opening through which the drawer moves between the presentation position and retracted position, wherein the front opening is alignable with a side opening of the access station compartment in the framework structure.

In one example useful for understanding the invention to which this European patent relates, the drawer front is aligned with the front opening when the drawer is in the retracted position.

In one example useful for understanding the invention to which this European patent relates, the frame comprises vertical side guiding plates for guiding the drawer as it extends out to the presentation position and as it retracts to the retracted position.

In one example useful for understanding the invention to which this European patent relates, the vertical side guiding plates are a snug fit to the drawer front to reduce gaps therebetween and thereby a possible risk of crushing fingers/hands during movement of the drawer. In one example useful for understanding the invention to which this European patent relates, a resilient material is positioned between the vertical side guiding plates and the drawer front to reduce gaps and risks further.

In one example useful for understanding the invention to which this European patent relates, the frame comprises a horizontal lower guiding plate for guiding the drawer. This lower guiding plate may be a snug fit to the drawer front to reduce gaps therebetween and thereby a possible risk of crushing fingers/hands during movement of the drawer.

In one example useful for understanding the invention to which this European patent relates, the drawer base comprises a support on which a storage container can be supported in a front position or in a rear position.

In one example useful for understanding the invention to which this European patent relates, the access station comprises a second actuator for moving a storage container from the front position to the rear position;
wherein the storage container is presented to a picker when the storage container is in the front position and when the drawer is in the presentation position.

In one example useful for understanding the invention to which this European patent relates, the access station comprises a control system.

The control system may be configured to control the first and second actuators based on input from a user interface system and a safety mechanism.

The control system may be configured to control the cover module and the conveyor module based on input from the user interface system and a safety mechanism.

In one example useful for understanding the invention to which this European patent relates, the user interface system and/or the safety mechanism may be provided outside of the access station compartment when the access station is inserted into the access station compartment.

In one example useful for understanding the invention to which this European patent relates, the control system is secured to the frame. In one example useful for understanding the invention to which this European patent relates, the control system is provided in communication with a control system for the automated storage and retrieval system.

In one example useful for understanding the invention to which this European patent relates, the vertical side guiding plates and the horizontal lower guiding plate may extend/protrude from the access station compartment when the access station is inserted into the access station compartment.

In one example useful for understanding the invention to which this European patent relates, a storage container retrievable from the drawer via the top opening and/or the drawer can receive a storage container via the top opening.

In one example useful for understanding the invention to which this European patent relates, the front position is located below the top opening when the drawer is in the retracted position and wherein the rear position is located below the top opening when the drawer is in the presentation position.

In one example useful for understanding the invention to which this European patent relates, the access station is configured to:.

In one example useful for understanding the invention to which this European patent relates, the second actuator is configured to move the storage container from the front position to the rear position when the drawer is in the retracted position or when the drawer is moving from the presentation position to the retracted position.

In one example useful for understanding the invention to which this European patent relates, the frame comprises a guard defining an upper border of the front opening.

In one example useful for understanding the invention to which this European patent relates, the safety mechanism is configured to prevent an object from being squeezed between the drawer front and the guard during movement of the drawer from the presentation position to the retracted position.

In one example useful for understanding the invention to which this European patent relates, the safety mechanism comprises:.

In one example useful for understanding the invention to which this European patent relates, the flap element is movably connected to a flap holding structure secured to the frame.

In one example useful for understanding the invention to which this European patent relates, the flap holding structure is a supporting structure for a user interface system.

In one example useful for understanding the invention to which this European patent relates, the support comprises rollers for supporting the storage container in the rear position.

In one example useful for understanding the invention to which this European patent relates, the support comprises a weight sensor for measuring a weight of the storage container when supporting the storage container in the front position.

In one example useful for understanding the invention to which this European patent relates, the second actuator comprises an electric motor and an actuating element movable by means of the electric motor.

In one example useful for understanding the invention to which this European patent relates, the drawer front and the guard are vertically aligned when the drawer is in the retracted position.

In one example useful for understanding the invention to which this European patent relates, the drawer comprises a container stop for preventing movement of the storage container from the front position towards the rear position when the drawer is in the presentation position.

In one example useful for understanding the invention to which this European patent relates, other parts of the framework structure comprises horizontal members. In one example useful for understanding the invention to which this European patent relates, such horizontal members are integrated with the rail system.

According to the above, it is a achieved system in which a first access station may be replaced with a second access station in a simple and efficient way, in case the first access station needs repair, maintenance or service.

According to the above, it is achieved a system where the number of ports may be increased in an easy and cost-efficient way. In an initial phase, the system may comprise an initial number of access stations and an initial number of container handling vehicles. In a later phase, the capacity of the system may be increased by providing the side opening for the access station compartment in the panel and then inserting the access station. Before installation of the access station <NUM>, the columns of the access station compartment may be used for stacking storage containers. Container handling vehicles may or may not be added as well.

In one example useful for understanding the invention to which this European patent relates, the access station compartment is located below at least one column of the framework structure. The column may be a port column, i.e. which are not intended for a stack of storage containers, or a storage column which are intended for a stack of storage containers.

As used herein, the term "access station" is a station enabling access to a storage container. The station is typically enabling access for an operator to the storage container, but may also enabling access for a robot, for example a picking robot, to the storage container. The access station may typically be a picking or a stocking station where product items are removed from or positioned into the storage container. In a picking or a stocking station, the storage containers are normally not removed from the automated storage and retrieval system, but are returned into the framework structure again once accessed.

The present invention also relates to a method for installation and/or de-installation of an access station, according to claim <NUM>, in an automated storage and retrieval system, wherein the method comprises the following steps:.

In one example useful for understanding the invention to which this European patent relates, the step of inserting the access station comprises:.

In one example useful for understanding the invention to which this European patent relates, the step of retrieving the access station comprises:.

It is now referred to <FIG>, where an access station <NUM> is shown. The access station allows a storage container <NUM> from an automated storage and retrieval system <NUM> to be presented to a picker P (the picker P being shown in <FIG>). The access station <NUM> may also be referred to as a port.

The access station <NUM> comprises an access module <NUM> comprising a frame <NUM> defining a drawer compartment <NUM> provided within the frame <NUM>. The drawer compartment <NUM> is also indicated as a dashed box <NUM> in <FIG>.

The access station <NUM> further comprises a drawer <NUM> movably connected to the frame <NUM>.

In <FIG> and <FIG>, it is further shown that the access station <NUM> comprises a front opening indicated as a dashed rectangle <NUM>. The front opening <NUM> is typically oriented in a vertical plane P22 shown in <FIG>.

It is further shown in <FIG> that the access station <NUM> comprises a top opening indicated as a dashed rectangle <NUM>. The top opening <NUM> is provided in a horizontal plane.

It is also shown in <FIG> that the access station <NUM> comprises an access opening <NUM> through which the content of the storage container <NUM> is accessible for the picker P.

The access station <NUM> further comprises a first actuator <NUM> for moving the drawer <NUM> relative to the frame <NUM> between two positions referred to as a presentation position PP and a retracted position RP. The presentation position PP is shown in <FIG> and <FIG>. Here, the drawer <NUM> is protruding from the drawer compartment <NUM> and a storage container <NUM> is presented to a picker P. The retracted position RP is shown in <FIG>. Here, the drawer <NUM> is retracted within the drawer compartment <NUM> and hence, no storage container <NUM> is presented to the picker P.

The access station <NUM> further comprises a second actuator <NUM>. The second actuator <NUM> and other details of the access station <NUM> will be described in detail below.

The access station <NUM> may also comprise a control system CS for controlling the first and second actuators <NUM>, <NUM>. The control system CS may be a part of the control system <NUM> for the automated storage and retrieval system, or the control system CS may be a separate control system in communication with the control system <NUM> for the automated storage and retrieval system.

The drawer <NUM> comprises a drawer base <NUM> movably connected to the frame <NUM> and a drawer front <NUM>. The drawer base <NUM> comprises a support <NUM> on which two storage containers <NUM> can be supported, as shown in <FIG> and <FIG>. The position of the storage container <NUM> being located closest to the front <NUM> is referred to as a front position P1, while the position of the storage container <NUM> being located distant from the front <NUM> is referred to as a rear position P2.

It is now referred to <FIG> and <FIG>. Here it is shown that the support <NUM> comprises rollers or wheels <NUM> for supporting the storage container <NUM> in the rear position P2. The support <NUM> also comprises a weight sensor <NUM> for measuring a weight of the storage container <NUM> when supporting the storage container <NUM> in the front position P1. A storage container <NUM> may slide along the weight sensor <NUM> and further onto the wheels <NUM> without much resistance.

The second actuator <NUM> is mounted to the drawer base <NUM> and comprises an electric motor 64a and an actuating element 64b in the form of a vertical plate movable by means of the electric motor 64a along a guide or rail 62c. The second actuator <NUM> may then push a storage container <NUM> from the first position P1 to the second position P2, as will be described further in detail below. It should be noted that due to the sliding surface of the weight sensor <NUM> and due to the wheels <NUM>, the power required to move the storage container <NUM> is relatively low.

The electric motor 64a is here a linear motor. However, the electric motor 64a could also be a rotating motor for moving the actuating element 64b by means of a chain drive, a belt drive etc..

The drawer <NUM> is provided within the drawer compartment <NUM> in the retracted position RP and at least partially protruding from the framework structure <NUM> in the presentation position PP. In the presentation position PP, the storage container in the first position P1 is accessible for the picker P, while the storage container in the second position P2 is still provided withing the drawer compartment <NUM>.

The drawer further comprises wheels <NUM>, <NUM> secured below the drawer base <NUM>, on the rear side of the drawer front <NUM>. The wheels <NUM>,<NUM> are running on plate 24c2 and on the horizontal lower guiding plate 22c during the movement of the drawer between its retraced position and its presentation position. In the present embodiment, the horizontal lower guiding plate 22c is a continuation of the plate 24c2, i.e. they are made as one plate member.

In <FIG> it is shown that the frame <NUM> comprises two side plates 24a and cross members 24b connecting the two side plates to each other. The two side plates 24a are also connected to each other by means of an upper horizontal cross plate 24c1, where storage containers <NUM> can be stacked above each other on the horizontal cross plate 24c1 in column 105B. The two side plates 24a are also connected to each other by means of a lower cross plate 24c2.

It is now referred to <FIG>, <FIG>, wherein it is shown that the access module <NUM> is partially integrated with the framework structure <NUM>. In <FIG>, the plane P22 of the front opening <NUM> is defining a separation plane between a front side FS outside of the framework structure <NUM> and a rear side RS inside of the framework structure <NUM>. The plane P22 is parallel to, and has a short distance (preferably a few centimetres) from, panels PA secured to the outer upright members <NUM> of the framework structure <NUM>. Alternatively, the panels themselves may be define the separation plane between the front side FS and the rear side RS.

The rear side RS is shown in <FIG>. Here, it is shown that the frame <NUM> comprises lintels 102a for supporting upright members <NUM> of the framework structure <NUM>. Hence, the frame <NUM> is forming a support for some of the upright members <NUM> of the framework structure <NUM>.

In <FIG>, a row of storage columns 105A are located adjacent to the panels PA. The next row of storage columns is indicated as storage columns 105B, and the next row of storage columns again is referred to as storage columns 105C.

As shown, the frame <NUM> has a footprint area A20 within the framework structure <NUM> corresponding to an area of two storage columns including at least parts of the area of surrounding upright members <NUM>. In <FIG>, the area of the top opening <NUM> is substantially equal to the area of one storage column 105A, which again is equal to an area A105B of the adjacent storage column 105B, which again is equal to the area of the other storage columns. As shown, the footprint area A20 is larger than the sum of the area of the top opening <NUM> and the area A105B, as parts of the areas of surrounding upright members <NUM> are included in the footprint area A20. The footprint area A20 is here defined as the area limited by the centre axis through six upright members enclosing two storage columns 105A, 105B.

In <FIG>, it is further shown that the footprint area A20 has a width W20 corresponding to one storage column width and a depth D20 corresponding to two storage columns depths measured between adjacent centre axis of the upright members <NUM>.

It should be noted that above, the footprint area A20 is defined as the rear side footprint area A20, i.e. the footprint area A20 within the framework structure <NUM>. This footprint area A20 is an indication of reduction of the storage capacity of the automated retrieval and storage system <NUM> due to the access station <NUM>.

In an alternative embodiment, the two side plates 24a are also connected to each other by means of a horizontal cross plate 24d (shown in <FIG>), where storage containers <NUM> can be stacked above each other on the horizontal cross plate 24d in column 105C. In this case, the frame <NUM> has a footprint area A20 within the framework structure <NUM> corresponding to an area of three storage columns including at least parts of the area of surrounding upright members <NUM>. It should be noted that the function of the horizontal cross plate 24d may be provided with a separate plate connected between upright members <NUM> of the framework structure <NUM>. Hence, the function of the horizontal cross plate 24d is not necessarily a part of the access station <NUM> per se.

In <FIG>, it is shown that on the front side FS, the frame <NUM> comprises vertical side guiding plates 22b for guiding the drawer front <NUM> as it extends out to the presentation position PP and as it retracts to the retracted position RP. The frame <NUM> also comprises a horizontal lower guiding plate 22c for guiding the lower end of the drawer front <NUM>.

The vertical side guiding plates 22b and the lower guiding plate 22c are a snug fit to the drawer front <NUM> to reduce gaps and a possible risk of crushing fingers/hands during movement of the drawer <NUM>.

The side guiding plates 22b and the lower guiding plate 22c are fixed in relation to the access station and the automated storage and retrieval system <NUM> and is therefore visible for the picker P and other persons working near the framework of the system <NUM>. Hence, when the drawer <NUM> is moved from the retracted position RP to the presentation position PP, this movement will not create a surprising obstacle for nearby personnel, as the drawer front <NUM> is moved in the space between the vertical guiding plates 22b and the lower, horizontal guiding plate 22c.

It is now referred to <FIG>, wherein it is shown that the frame <NUM> comprises a guard 22d defining an upper border of the front opening <NUM>. The side guiding plates 22b, the lower guiding plate 22c and the guard 22d in the vertical plane P22 together define the borders of the front opening <NUM>, as indicated in <FIG> and in <FIG>.

The first actuator <NUM> is mounted to the lower cross plate 24c2 and comprises a linear motor 62a, an actuator element 62b and a guide 62c for guiding the linear movement of the actuator element 62b. The actuator element 62b is connected to the underside of the drawer <NUM>, as shown in <FIG> and <FIG>.

It is now referred to <FIG>, where it is shown that the access station <NUM> comprises a safety mechanism <NUM> for preventing an object (typically the pickers fingers/hands) from being squeezed between the drawer front <NUM> and the guard 22d during movement of the drawer <NUM> from the presentation position PP to the retracted position RP.

The safety mechanism <NUM> comprises a flap element 66a provided adjacent to, and on the front side FS of, the guard 22d, and a sensor 66b for sensing movement of the flap element 66a relative to the guard 22d. The flap element 66a is movably connected to a flap holding structure 66c secured to the frame <NUM> by means of one or more hinges 66d.

In one aspect, the flap holding structure 66c is secured to the guard 22d. In one aspect, the flap element 66a is movably connected to the flap holding structure 66c by means of one or more hinges 66d.

The flap holding structure 66c is a supporting structure for a user interface system <NUM>, for example comprising a touch screen or other type of user interface.

The sensor 66b may be an integrated circuit type of sensor, such as an accelerometer etc., connected to the first actuator <NUM>. The sensor 66b may be a push-button type of security switch, which are activated by the movement of the flap element 66a. Sensors 66b of this type are known to a person skilled in the art.

When activated, the sensor 66b controls the first actuator <NUM> to stop the movement of the drawer or controls the first actuator <NUM> to move the drawer <NUM> out from the compartment <NUM> again. The sensor 66b may also control the second actuator <NUM> to stop the movement of the actuating element 64b or to move in the reverse direction. The sensor 66b may be connected directly to the first and/or second actuator <NUM>,<NUM>. Alternatively, the sensor 66b is connected to the first and/or second actuator <NUM>,<NUM> via the control system CS.

It is now referred to <FIG>, where two double-headed arrows are referred to as DA and DB. The first double-headed arrow indicates a first distance DA between the flap element 66a and the storage container in <NUM> in the front position P1. This distance is needed to be able to obtain access to the storage container <NUM> in the first position when the drawer <NUM> is in the presentation position PP and to be able to lift the storage container in the first position P1 up/down through the top opening <NUM> when the drawer is in the retracted position RP. The second double-headed arrow indicates a second distance DB between the storage container <NUM> in the front position P1 and storage container <NUM> in the rear position P2. This distance is needed to be able to be able to lift the storage container in the second position P2 up/down through the top opening <NUM> when the drawer is in the presentation position PP. The first distance DA is equal to, or substantially equal to the second distance DB.

In <FIG>, it is shown that the drawer <NUM> in the retracted position RP projects into the third column 105C. Hence, even if the frame <NUM> only has a footprint area A20 of two storage columns including at least parts of the area of surrounding upright members <NUM>, the drawer <NUM> will prevent storage containers <NUM> from being stacked in full height in the third storage column 105C. This is indicated as area A40 in <FIG>.

However, the plate 24d described above may allow storage containers to be stacked also in the third column 105C, the third column 105C having a reduced stacking height corresponding to the height H20 of the frame <NUM>.

The different steps for operation of the access station <NUM> are shown in <FIG>.

Initially, in <FIG>, there are no storage containers <NUM> in the drawer <NUM> and there is no storage container <NUM> in the buffer position P3 in the first storage column 105A. The drawer <NUM> is in the retracted position RP.

In a first step a) (<FIG>) the access station <NUM> receives a first storage container 106A. A container handling vehicle <NUM>, <NUM> is controlled to pick a first storage container 106A from one of the storage columns <NUM> in the framework structure <NUM> and to lower it down into the front position P1 of the drawer <NUM>. On its way down the storage column 105A, the first storage container 106A will pass the buffer position P3.

In a second step b) (<FIG>), the first actuator <NUM> is controlled to move the drawer <NUM> to the presentation position PP. Here, the first storage container 106A is presented to the picker P.

In a third step c) (<FIG>), the first actuator <NUM> is controlled to move the drawer <NUM> to the retracted position RP within the access module <NUM>. In a next step d), the second actuator <NUM> is controlled to move the first storage container 106A from the front position P1 to the rear position P2 of the drawer <NUM>. It should be noted that step c) may be performed before step d). Alternatively, step c) and d) may be performed simultaneously or substantially simultaneously. The safety mechanism will stop the movement of the drawer <NUM> if a finger/hand is located within the storage container on its way into the compartment <NUM> and will also stop the movement of the drawer <NUM> if a finger/hand is located between the front plate and the storage container on its way into the compartment <NUM>.

After step c) and d), the drawer <NUM> is in the retracted position RP and the first storage container 106A is in the rear position P2. The actuator element 64b will now return to its original position close to the front <NUM> of the drawer <NUM>.

During or after step c) and d), the container handling vehicle <NUM>, <NUM> may be controlled to pick a second storage container 106B from one of the storage columns <NUM> in the framework structure <NUM> and to lower it down to the buffer position P3.

In a next step e) (<FIG>), the access station <NUM> receives the second storage container 106B from the buffer position P3. The second storage container 106B is lowered down into the front position P1 of the drawer <NUM>. It should be noted that the container handling vehicle <NUM>, <NUM> may hold the second storage container 106B stationary in the buffer position P3 while waiting for steps c) and d). However, the container handling vehicle <NUM>, <NUM> may also be coordinated with the access station <NUM> so that there is no waiting time for the second storage container 106B in the buffer position P3.

In a next step f) (<FIG>), the first actuator <NUM> is controlled to move the drawer <NUM> to the presentation position PP in which the second storage container 106B is presented to the picker P.

During or after step f), the first storage container 106A is retrieved from the rear position P2 by means of a container handling vehicle <NUM>, <NUM>.

In a next step g) (<FIG>), the first actuator <NUM> is controlled to move the drawer <NUM> to the retracted position RP within the access module <NUM>. In a next step h), the second actuator <NUM> is controlled to move the second storage container 106B from the front position P1 to the rear position P2 of the drawer <NUM>. Hence, steps g) and h) are similar to the above steps c) and d).

The actuator element 64b will now return to its original position close to the front <NUM> of the drawer <NUM>.

During or after step f) and h), the container handling vehicle <NUM>, <NUM> may be controlled to pick a third storage container 106C from one of the storage columns <NUM> in the framework structure <NUM> and to lower it down to the buffer position P3.

It is now referred to <FIG>. Most of the technical features of the access station <NUM> and the operation of the access station <NUM> is identical to or similar to the embodiment described above. Only differences between the embodiment described above and this alternative embodiment will be described below.

First, it should be noted that the first actuator <NUM> and the second actuator <NUM> works substantially in the same way as in the above embodiment.

The first actuator <NUM> comprises an electric rotating motor 62a for driving a belt 64d, to which the actuator element 62b is connected. The actuator element 62b is further connected to the drawer <NUM> and the drawer <NUM> is moved by means of the electric rotating motor 62a via the belt 62d and the actuator element 62b. The movement of the actuator element 62b is guided along rails 62c engaged with the actuator element 62b.

It is now referred to <FIG>. Here it is shown that the access station <NUM> comprises a presentation position sensor 72a and a retracted position sensor 72b. It is also shown that the actuator element 62b comprises a sensor engaging part 72c, here in the form of a bracket protruding to a position in which the sensor engaging part 72c is brought adjacent to, or in contact with, the presentation position sensor 72a when the drawer <NUM> is in the presentation position PP and adjacent to, or in contact with, the retracted position sensor 72b when the drawer <NUM> is in the retracted position. The sensors 72a, 72b may be optical sensors, capacitive sensors, a contact-type of sensor etc. The sensors 72a, 72b are connected to the control system CS.

In <FIG> and <FIG> it is further shown an energy chain <NUM> for guiding and protecting electrical conductors and signal conductors between the control system CS and the weight sensor and electric motor of the drawer.

In <FIG>, it is shown that the access station <NUM> comprises a further safety system comprising a rail 71a for guiding a linear movement of a first magnet element 71b. The first magnet element 71b is connected to, and driven by, the belt 62d of the second actuator <NUM>. A second magnet element 71c is connected to the actuating element 62b of the second actuator <NUM>. The first and the second magnet elements 71b, 71c are magnetically connectable to each other.

It is now assumed that the drawer <NUM> (and hence the actuator element 62b) are in the retracted position. The belt 62d, including the first magnet element 71b is now moved by means of the motor 62a. Due to the magnetic coupling between the first and second magnet elements 71b, 71c, the first magnet element 71b will pull the actuating element 62b towards the presentation position PP as the belt moves. If the drawer <NUM> is held back, for example by an object obstructing the movement of the drawer from the retracted position RP to the presentation position PP, the first and the second magnet elements 71b, 71c will be pulled away from each other, causing the drawer <NUM>, the actuating element 62b and hence the second magnet element 71c to stop while allowing the first magnet element 71b and the belt 62d to continue its linear movement. During movement of the first magnet element 71b and the belt 62d back to their initial position, the first magnet element 71b will reconnect to the second magnet element 71c again.

The second actuator <NUM> comprises a rotating electric motor 62a for driving a belt 64d to which the actuator element 64b is connected. The actuator element 64b is moved by means of the electric rotating motor 64a via the belt 64d. The movement of the actuator element 64b is guided along rails 64c engaged with the actuator element 64b.

It is now referred to <FIG>. Here, details of a container stop <NUM> is illustrated. Initially, it should be mentioned that the drawer base <NUM> is supported on the plate 24c via the actuating element 62b of the second actuator <NUM> and by wheels <NUM>, <NUM> connected to each other by means of a wheel connector member <NUM>.

The container stop <NUM> comprises a profile <NUM> secured to the plate 24c2, the profile having a lowered profile section 81a, an elevated profile section 81b and an intermediate, inclining, profile section 81c between the profile sections 81a, 81b.

The container stop <NUM> further comprises a container stop element <NUM> secured to the wheel connector member <NUM>.

The rear wheels <NUM> are running on top of the profile <NUM>. In <FIG> the drawer is in the presentation position (PP). Here, the rear wheels <NUM> are located on the elevated profile section 81b, causing the rear part of the wheel connector member <NUM> to tilt upwardly, and hence causing the container stop element <NUM> to protrude up on the rear side of the storage container <NUM> in the front position P1. Movement of the storage container <NUM> from the front position to the rear position (for example by a person trying to push the storage container) is now prevented. It is also possible for the container stop element <NUM> to prevent the storage container <NUM> to be lifted up from the drawer in the presentation position (to prevent theft etc).

In <FIG>, the drawer is in the retracted position (RP). Here, the rear wheels <NUM> are located on the lowered profile section 81a, causing the rear part of the wheel connector member <NUM> to tilt downwardly, and hence causing the container stop element <NUM> to retract down from the rear side of the storage container <NUM> in the front position P1. Movement of the storage container <NUM> from the front position to the rear position by means of the second actuator <NUM> is now allowed.

It should be noted that in the first embodiment of the access station <NUM> described above, the access module <NUM> is integrated with the framework structure, due to the frame <NUM> comprising lintels 102a for supporting the upright members <NUM> from below. Hence, service, maintenance and repair operations of the access station may be cumbersome.

In the second embodiment shown in <FIG>, the frame <NUM> is not supporting the upright members <NUM> from below. Instead, the access module <NUM> is one single independent access module with a self-supporting frame <NUM> provided with wheels <NUM>.

Here, the framework structure <NUM> comprises an access station compartment <NUM> having a side opening <NUM> which can be covered by a panel (PA) when not in use. The access station <NUM> is then insertable into and retrievable from the access station compartment <NUM> by rolling the access station <NUM> into and out from the side opening <NUM>. The access station <NUM> comprises a jack for elevating an upper portion of the access station <NUM> upwardly within the access station compartment <NUM>, for example up towards a roof portion <NUM> within the access station compartment <NUM>, the roof portion <NUM> being defined by the downwardly facing surfaces of the horizontal members <NUM>. It is also shown in <FIG> that a support plate <NUM> is secured below the lower ends of the upright members 95a. The wheels <NUM> of the access station <NUM> are supported onto this support plate <NUM> when inserted into the access station compartment <NUM>.

In <FIG>, it is shown that the framework structure <NUM> comprises a receptacle frame <NUM> defining the access station compartment <NUM>, wherein the receptacle frame <NUM> is forming a support for a plurality of upright members <NUM>. In <FIG>, the receptacle frame <NUM> comprises upright frame members 95a, which are connected to each other by means of cross-members 95b, <NUM>.

A similar embodiment of the receptacle frame <NUM> is shown in <FIG>. Also here, the receptacle frame <NUM> comprises upright frame members 95a and cross-members 95b. It is also here shown how the receptacle frame <NUM> is forming a support for a plurality of upright members <NUM> of the framework structure <NUM>.

In <FIG> it is further shown that the width D90 of the access station compartment <NUM>, measured as the distance between two upright frame members 95a, is larger than a distance D102 between two upright members <NUM>. In the present example, the upright frame members <NUM> are used to guide the storage containers vertically. To be able to move the storage container horizontally within the access station <NUM>, the width D10 of the access station <NUM> must be wider than the distance D102 between two upright members <NUM>. It should be noted that the width D90 and the distance D102 are measured perpendicular to the direction of horizontal movement HM of the storage container <NUM> in the access station <NUM> (as indicated in <FIG>).

It is now referred to <FIG>. Here it is shown an access station <NUM> comprising three modules. The first module is referred to as a main module <NUM> secured to the outside of the framework structure <NUM>. The main module <NUM> receives a storage container <NUM> during a picking/supply operation. The main module <NUM> is surrounding the opening <NUM> to the access station compartment <NUM>.

The second module is a cover module <NUM> provided above the main module <NUM> for controlling access to the storage container <NUM> when received by the main module <NUM>. The second module <NUM> is shown from below in <FIG> and comprises an opening 14a which can be closed and opened by a movable cover 14b. The control system CS of the access station <NUM> is also integrated in the cover module <NUM>. Also the actuator (not shown) operating the movable cover 14b is provided as a part of the control system CS. It should be noted that the movable cover 14b is provided with a safety mechanism <NUM> to prevent pinch injuries etc..

The third module is a conveyor module <NUM>. The conveyor module <NUM> comprises a conveyor belt, rollers and motors for powering the conveyor belt. The conveyor module <NUM> can easily be mounted to the receptacle frame <NUM> by means of drawer slides 95c (<FIG>). As shown in <FIG>, the conveyor module <NUM> will be located below the top opening <NUM>. Hence, storage containers <NUM> will be lowered onto the conveyor module <NUM> via the column <NUM> and the top opening <NUM> by means of container handling vehicles similar to the embodiments described above, and storage containers <NUM> will be elevated from the conveyor module <NUM> through the top opening <NUM> and the column <NUM> by means of container handling vehicles similar to the embodiments described above.

The control system CS is connected to the conveyor module <NUM> and also to the central control system <NUM> of the automated storage and retrieval system <NUM>.

In <FIG>, it is shown that the access station <NUM> further comprises a user interface <NUM> in the form of a computer terminal having a display, keyboard and mouse. Alternatively, the user interface <NUM> may be integrated in the cover module <NUM>.

In <FIG>, the sequence of removing the access station <NUM> is shown. In a first step shown in <FIG>, the cover module <NUM> is removed from the main module <NUM>. In <FIG> the main module <NUM> is removed from the opening <NUM>. In <FIG>, the conveyor module <NUM> is retrieved from the opening <NUM>. A new conveyor module <NUM> may now be inserted into the opening. Alternatively, the drawer slides 65c may be pushed into the compartment <NUM> and the opening <NUM> may be closed by means of a panel hatch.

The steps of installing the access station <NUM> is performed in the opposite sequence.

In the above description, the vertical movement of the storage containers through the top opening <NUM> is performed by container handling vehicles <NUM>, <NUM>. Alternatively, a type of container lift may be used to move the storage containers vertically to and from the access station <NUM>.

In the above embodiment, the access station <NUM> occupies one storage column 105A for vertical transportation of storage containers, and two other storage columns 105B, 105C has reduced storage capacity due to the footprint areas A20, A40.

By reducing the first and second distances DA, DB, it is possible to achieve full storage capacity in the third storage column 105C. This may require a different and/or more space-efficient safety mechanism. One such possible safety mechanism is a movement detection type of sensor, for example a photoelectric sensor for sensing whether or not a finger/hand is present in the area close to the access opening <NUM> and or the front opening <NUM> during movement of the drawer <NUM> towards the retracted position RP.

Claim 1:
An automated storage and retrieval system (<NUM>) comprising a framework structure (<NUM>), wherein the framework structure (<NUM>) comprises:
- upright members (<NUM>);
- a storage volume comprising columns (<NUM>) provided between the members (<NUM>), wherein storage containers (<NUM>) are stackable in stacks (<NUM>) within the columns (<NUM>); and
- a rail system (<NUM>) provided on top of the members (<NUM>);
wherein the automated storage and retrieval system (<NUM>) comprises:
- an access station (<NUM>); and
- container handing vehicles (<NUM>, <NUM>) configured to move on the rail system (<NUM>);
- the framework structure (<NUM>) comprises an access station compartment (<NUM>);
wherein the access station (<NUM>) is insertable into and retrievable out from the access station compartment (<NUM>), characterised in that the access station (<NUM>) comprises a jack for elevating an upper portion of the access station (<NUM>) upwardly within the access station compartment (<NUM>).