Patent Description:
We are aware of the publication <CIT>, in which the main object of the invention is a system for storing and handling items in stacks of trays, where trays with items are stored in stacks on storage locations placed in two mutually perpendicular horizontal directions. For picking up, placing and moving the stacks of trays, there are transport mobile devices that move along the transport network of the system and independently pick up and place the stacks of trays from the storage locations. Moreover, <CIT> includes a device for re-sorting the stacks of trays so that the target tray can be turned into a top tray with a minimum number of manipulations. The tray stacks are transported to the tray re-sorting device by means of transport mobile devices. A variant version of the storage and handling system according to <CIT> is shown in <FIG> of this document.

<CIT> discloses a storage and retrieval system in which items are stored in containers. The containers are arranged in stack units. Each stack unit comprises a stand comprising a stand top and one or more legs extending downwardly from the stand top. The containers are arranged in a stack on top of the stand top. Each stack unit is movable by a vehicle dimensioned to allow the vehicle to move underneath the stand top. Each vehicle comprises a lifting mechanism moveable between a raised position and a lowered position to raise the stack unit off the ground and lower the stack unit onto the ground respectively.

<CIT> teaches an automated storage retrieval system and method for receiving and delivering goods using a pickup device are provided. According to an embodiment, the automated storage retrieval system includes: a plurality of vertically loaded goods vertically stacked without a separate loading rack; a goods pickup device that includes a goods lift configured to lift at least one in a column of the vertically loaded goods in a vertical direction and a goods picker configured to approach a space generated by being lifted by the goods lift to take out goods placed in the space or load the goods into the space; and a goods buffer unit configured to carry the goods to take out or load the goods. In addition, an item picking method that directly takes out an item in goods instead of taking out the goods is also disclosed.

<CIT> discloses a storage and sorting system comprising at least one stack of trays the stack of trays comprises at least two trays stacked on top of each other, a mobile transport unit is provided on which the stack of trays is transportable, a sorting apparatus is provided, respectively, wherein the sorting apparatus comprises:.

The disadvantages of the storage and handling system of the prior art are.

According to the present invention an automatic device for picking items directly from a stack of trays, as well as the method of operation of the device and an improved method of storing items in trays is claimed.

Thus, by improving the way items are stored inside the stack trays by adding multiple levels of pallets divided into cells to each tray, we gain the following advantages over the prior art publication system:.

At the same time, the automatic item picking device itself, consisting of a tray gripper, a pallet gripper and an item gripper in various combinations, provides the following advantages over a re-sorter from a publication:.

The main object of the present invention is an automatic apparatus for picking items directly from a stack of trays, as well as a method of operating the apparatus and a method of storing the items in the trays. The automatic item picking device in the present invention comprises the following modules: a first module providing access to any tray of the stack of trays; a second module providing access to any palette in any of the trays of the stack; a third module providing movement of an item from a donor tray to an acceptor tray - picking device. The above-mentioned modules of the device may be implemented either separately or in a single body. In addition, to implement the present invention, a new method of storing objects in stacks of pallets divided into a different number of cells, the size of which may be determined by the size of the objects stored in them, placed inside each tray in several levels, is proposed.

<FIG> shows an automatic item picking device (<NUM>) directly from a brought stack of trays configured to operate in a stackable tray storage system (<NUM>), linked to it by transport tracks (<NUM>), in which automatic transport mobile devices (<NUM>) are used to feed stacks of trays (<NUM>).

As shown in <FIG>, the automatic device for picking items directly from a delivered stack of trays (<NUM>) comprises:.

The load platform may be part of a vertical arrangement for lifting up the mobile transport device with the stacks of trays or just the stacks of tray upwardly to a position in which the grippers (<NUM>) may grab the stack, a sub-stack or a single tray from that stack. The load platform may be adapted as an elevator for the mobile transport device with a stack of trays or for the stack itself.

The grippers may be arranged adjacent to the load platform in a horizontally static manner or adaptable in height. The grippers are preferably arranged on different, preferably opposite side of the load platform.

<FIG> shows a section of a storage and handling system (<NUM>) for stackable trays known from <CIT>, equipped with transport tracks (<NUM>) configured for operation of automatic transport mobile devices (<NUM>) thereon.

<FIG> shows a mobile transport device (<NUM>) with a stack of trays (<NUM>) standing on the MTU, in accordance with the current state of the art known from publication <CIT>.

<FIG> and <FIG> show an improved way of storing different objects (A, B, C) in the same tray (<NUM>). <FIG> shows a tray (<NUM>) filled with different objects (A, B, C) lying on different pallets (<NUM>, <NUM>, <NUM>). <FIG>, for clarity, shows the same tray (<NUM>) with its contents extracted and the way it is filled.

As can be seen from the figure inside the tray (<NUM>) a stack of pallets (<NUM>, <NUM>, <NUM>) are stored, divided into different numbers of cells: thus, the pallets (<NUM>) are e.g. divided into two cells, the pallets (<NUM>) e.g. into four, the tray (<NUM>) e.g. into eight, and exemplary items (A), (B) and (C) are stored in them according to the size of the cells. The figure shows a stack of three pallets in one tray and the number of cells in the trays two, four and eight, which is only an illustrative example to convey the essence of the invention, but is not intended to limit it. It is clear to the skilled person that both the number of trays in a stack and the number of cells in a pallet may be arbitrary. It is also clear to the skilled person that although the figure shows that the pallets hold different objects one in each cell of the pallets, each cell may hold more than one identical object, and all the pallets in the stack in the tray may be identical, etc..

Also, as can be seen from <FIG>, when stacking the pallets (<NUM>, <NUM>, <NUM>) inside the tray (<NUM>), the inner walls of the tray may guide the pallets and the corners of the pallets can be provided with indentations, through which the further grippers (<NUM>) of the automatic item picker pass from top to bottom directly from the brought tray stack during pallet picking/stacking. In this way, the further grippers (<NUM>) can pick up any number of the top pallets of the stack contained in the tray (<NUM>) in a single operation.

<FIG> shows the detailed sequence of steps in the operation of the automatic item picker (<NUM>) directly from a brought stack of trays.

For example, <FIG> shows the initial state of the automatic item picking device (<NUM>) directly from a brought stack of trays, in which an automatic transport mobile device (<NUM>) with a stack of trays (<NUM>) containing a target item for picking is driven onto the load platform (<NUM>) from the transport tracks (<NUM>). At the same time, in a first gripper (<NUM>) of the device (<NUM>) there is an acceptor tray (<NUM>) into which the target item is to be moved.

<FIG> shows the next step in the appliance's operating sequence, in which the load platform (<NUM>) is moved upwards so that a second gripper (<NUM>) of the appliance can remove the stack tray above the target item tray.

In <FIG>, the second gripper (<NUM>) of the device (<NUM>) grabs the tray above the target tray.

In <FIG> the second gripper (<NUM>) of the device (<NUM>) moves the held sub-stack of trays into the gripper's original position away from the working area of the load platform (<NUM>).

In the position shown in <FIG>, the load platform (<NUM>) has moved vertically upwards so that the further grippers (<NUM>) of the device (<NUM>) can remove the stack of pallets (<NUM>) located in the tray above the target item.

The load platform (<NUM>) has moved vertically downwards, aligning the stack tray standing on the MTU (<NUM>) with the target object with the object-acceptor held by the first gripper (<NUM>) of the device (<NUM>).

In <FIG>, preferably the movable platform (<NUM>) is moved horizontally to the left so that the object gripper (<NUM>), which can be attached to it from below, can move into the working area of the load platform (<NUM>). The object gripper (<NUM>) itself has moved within its working area to the coordinate corresponding to the position of the target object lying on the pallet (<NUM>) in the now upper tray (<NUM>) of the stack.

In <FIG>, the load platform (<NUM>) moves upwards so that it presses the target object lying in the top tray of the stack on the pallet against the object gripper (<NUM>).

<FIG> shows the following position of the operating device (<NUM>), in which the load platform (<NUM>) has moved lower, aligning the top tray of the stack of trays standing on the MTU (<NUM>) with the object-acceptor tray (<NUM>) held by the first gripper (<NUM>) of the device (<NUM>) or at least to move out of the way of the object gripper (<NUM>) so it can transfer the object C out of the source tray. The target item (C) is picked up by the object gripper (<NUM>).

In <FIG> the movable platform (<NUM>) or at least the object gripper (<NUM>) moves horizontally to the right so that the object gripper (<NUM>) with the object it holds (C) moves into position over the tray-acceptor (<NUM>) held by the first gripper (<NUM>) of the device (<NUM>). The movable platform (<NUM>) is moved back to a position above the load platform.

The following <FIG> shows the position in which the load platform (<NUM>) is moved upwards to bring the stack of pallets held by the further grippers (<NUM>) of the device (<NUM>) back into the upper tray (<NUM>) of the stack on the MTU (<NUM>). Preferably at the same time, the item gripper (<NUM>) holding the target item (C), previously taken from the stack tray, may move downwards in its working area to place the object within the object-acceptor (<NUM>) held by the first gripper (<NUM>) of the device (<NUM>).

In <FIG>, the object gripper (<NUM>) no longer holds the target object (C) and it falls by gravity into the target tray (<NUM>) held by the first gripper (<NUM>) of the device (<NUM>).

This is an accelerated method of stacking items during picking and may only be possible for a limited range of items. If an item is fragile or requires careful stacking for some other reason, the upper acceptor tray is moved onto the stack of trays standing on the MTU (<NUM>) into the working area of the load platform (<NUM>), then the acceptor tray is brought directly to the item gripper (<NUM>), which releases the retained item and it is stacked gently.

Preferably simultaneously and/or independently with/from the loading of the object (C) into the acceptor tray, in <FIG> the load platform (<NUM>) is moved downwards to such a height as to prepare the stack of trays for the return of the two upper trays of the stack previously withdrawn by the left grip (<NUM>) of the device (<NUM>).

Further, in <FIG>, the second gripper (<NUM>) of the device (<NUM>) moves the retained trays into the working area of the load platform (<NUM>), and returns them to their original position on the tray stack.

<FIG> shows the final position of the operation, in which the second gripper (<NUM>) returns empty to its original position, the load platform (<NUM>) moves to its lower position, the MTU (<NUM>) with the stack of trays on the load platform (<NUM>) aligns in height with the transport tracks (<NUM>) of the system, and can leave the device (<NUM>), which has completed the operation to move the target object (C) directly from the target tray of the previously brought stack into the acceptor tray. Generally, the second gripper could retain the trays for a different MTU to pick up and leave the device (<NUM>) without it.

<FIG> shows the position of the automatic picking device directly from the brought stack of trays (<NUM>), in which, after picking the next item, the acceptor tray (<NUM>) is full and it is replaced. In this case, the second gripper (<NUM>) of the device (<NUM>) may pick up and hold the entire stack of trays (<NUM>) brought earlier by the MTU (<NUM>), while the first gripper (<NUM>) of the device (<NUM>) moves the tray-acceptor (<NUM>) to the TMU (<NUM>).

Generally, the acceptor tray can also by placed on top or bottom or anywhere in the middle of the stack trays the received object C was delivered in or in any of those positions of a further stack that arrives later on.

<FIG> shows another aspect of the automatic item picking device (<NUM>) directly from a brought stack of trays configured to operate in a stackable tray storage system (<NUM>) preferably connected to it by transport tracks (<NUM>), in which automatic transport mobile devices (<NUM>) may be used to feed stacks of trays (<NUM>). Thus, the illustrated aspect shows the device (<NUM>) to be operated simultaneously by two MTUs (<NUM>) which may be adapted to bring stacks of trays (<NUM>) to it via the transport tracks (<NUM>). Furthermore, the combination of the mechanisms comprising the device may be different. The automatic item picking device directly from the brought stack of trays (<NUM>) may comprise at least of the following in any combination:.

Another aspect of the automatic picking device (<NUM>), shown here, may operates with at least one of the subsequent steps in any combination.

The presented aspect of the automatic appliance for the direct picking of objects from a stack of trays (<NUM>) may differ from the first version in the lack of a lifting platform (<NUM>) and preferably in other combinations of mechanisms: in the first variant, the tray grippers (<NUM>) may be combined with the load platform (<NUM>) and/or the pallet gripper (<NUM>) may be combined with the moving platform (<NUM>) and/or the item gripper (<NUM>); In the aspect shown (<NUM>), the tray gripper (<NUM>) and/or pallet gripper (<NUM>) may be mounted on a lifting beam (<NUM>) and may move upwards/downwards preferably in co-operation with the stacks of trays (<NUM>) mounted horizontally on the conveyor belts (<NUM>) of the MTU (<NUM>), the item gripper (<NUM>) preferably being also vertically displaceable by the lifting device (<NUM>) of which it is a part.

In the presented aspect of the automatic apparatus for picking items directly from a brought stack of trays (<NUM>) there may be one load carrier (<NUM>) equipped with two grippers of a stack of trays (<NUM>) and/or two grippers (<NUM>) of pallets, and/or a device equipped with one item gripper (<NUM>) preferably placed on a lift device (<NUM>) - the quantities mentioned above are only indicative, but not limiting to the invention.

<FIG> shows another aspect of an automatic item picking device directly picking from a stack of trays (<NUM>) which might have been delivered before, configured to operate in a tray stacking system (<NUM>), linked to it by transport tracks (<NUM>), in which automatic transport mobile devices (<NUM>) are used to feed stacks of trays (<NUM>).

In the device shown in <FIG>, all the mechanisms may be lined up above the transport tracks (<NUM>), along which preferably two MTUs (<NUM>) in particular from different sides (right and left) may deliver stacks of trays containing the target items to the device (<NUM>). Thus, the automatic item picking device for picking in particular directly from the brought stack of trays (<NUM>) may comprise at least one of the following in any combination:.

The operation in the presented third aspect of the apparatus (<NUM>) may proceed with at least one of the following steps in any combination.

The presented third aspect of the automatic apparatus in particular for picking items directly from a brought stack of trays (<NUM>), there may be no functionally connected devices, so that the tray gripper (<NUM>) may be separate and/or the pallet gripper (<NUM>) with the lift devices (<NUM>) may be separate, and/or the item gripper (<NUM>) with the load traverse (<NUM>) may be separate. As according to the second aspect of the device (<NUM>), in this aspect (<NUM>) there may be no vertical movement of the MTU (<NUM>) and/or its detachment from the level of the transport tracks (<NUM>). Otherwise, the methods of operation may be identical in all three aspects.

<FIG> shows an aspect of the invention, according to which the mechanisms (a - <NUM> and b - <NUM>) included according to previous aspects are duplicated three times. Thus, in this variant of the device there are three levelers with tray grippers (<NUM>), shown earlier in the third variant of the device, as well as three lifting devices (<NUM>) from the same variant, and as a component device there is one/single manipulator (<NUM>) moving vertically by means of a carriage (<NUM>), shown earlier in the second variant of the device.

The presence of three levelers with tray grippers (<NUM>) and three lifting devices (<NUM>) in three neighboring rows (of rail tracks (<NUM>)) or adjacent to each other, makes it possible to prepare/move target items (A, B, C. ) on/onto target pallets (<NUM>), (<NUM>) located in target trays (<NUM>) (of stacks of trays) brought by the MTU (<NUM>), as well as target pallets for placing items in three stacks at once, and to move them between these stacks by means of the manipulator (<NUM>). Also, the items may be moved between any three stacks of trays (<NUM>) located in the working area of the manipulator (<NUM>).

Thus, in each row of rail tracks (<NUM>), the stack of trays (<NUM>) is processed as follows:
The levelers with tray grippers (<NUM>) remove the trays (<NUM>) of the stack above the target tray.

The MTU(s) (<NUM>) may move into the working area(s) of the load lifter(s) (<NUM>), which remove(s) the pallets (<NUM>), (<NUM>) above the target pallet from the target tray(<NUM>).

The MTU (<NUM>) with the exposed target pallet(s) (<NUM>) or (<NUM>) located in the target tray(s) (<NUM>) of the stack(s) of trays move(s) to the working area of the manipulator (<NUM>), where the objects (A,B,C. ) are moved between the (three) and/ (similarly) prepared stacks of trays (<NUM>) / exposed target pallet(s) (<NUM>, <NUM>).

After the object manipulation is completed, any tray stack(s) brought in may be restored to its original state, regardless of the other tray stacks involved in the picking process, by means of the reverse sequence of actions.

Also, by means of reversing the sequence of actions required to reach the target tray or the target pallet, it is possible instead of restoring the initial state of the tray stack, to prepare the next target item or pallet for picking by shuttle movement of the MTU (<NUM>) (with the tray stack) between the devices ((<NUM>)) ->(<NUM>)->(<NUM>)->(<NUM>)->((<NUM>)), until the stock of the tray stack is exhausted or filled.

Thus, the presence of three adjacent (rows of rail tracks (<NUM>))/mechanisms a and b, thus the devices (<NUM>) and (<NUM>) and one common manipulator (<NUM>) allows for the picking of items both from a single donor stack of trays into a plurality of acceptor stacks of trays until the content of the donor stack of trays is completely exhausted, and for the complete filling of a single acceptor stack of trays from a plurality of donor stacks of trays. The donor stack may be provided via one of the three or more pathways <NUM> → <NUM> →<NUM>.

<FIG> illustrates another aspect of the invention of a picking device (<NUM>) comprising, similar to the previous aspect, three or more adjacent rows of rail tracks (<NUM>) / adjacent mechanisms a and b equipped with three or more tray grippers (<NUM>), three or more lifting devices (<NUM>), and a common manipulator (<NUM>), located above all three or more rows of rail tracks (<NUM>), below which are located load lifters (<NUM>), one in each row, designed to lift any upper target tray of the stacks of trays to the working height of the common manipulator (<NUM>).

The function of the device proposed in <FIG>, is basically identical to the way of operation of the last aspect of the invention according to <FIG> only with the difference that the cargo lifters (<NUM>) provide vertical movement of objects (A,B,C. ) and target pallets (<NUM>), (<NUM>) to the manipulator (<NUM>) instead of the manipulator (<NUM>) moving vertically between different heights of the tray on the MTU (<NUM>) between which the target items are shifted.

The aspect according to <FIG> has the same advantages as the previous variant according to <FIG> of the device proposed above, but in comparison with may have a slightly higher speed of picking items/resorting items between target pallets due to the presence of three load elevators (<NUM>).

Claim 1:
Storage and sorting system comprising at least
- one stack of trays (<NUM>)
o the stack of trays (<NUM>) comprises at least two trays (<NUM>) stacked on top of each other
o In each tray (<NUM>) there are at least two stacked sorting pallets (<NUM>, <NUM>,...) for individual storage of objects (A, B, C,...).
▪ Each pallet (<NUM>, <NUM>,...) comprises individual storage units of different size.
- a mobile transport unit (<NUM>) is provided on which the stack of trays (<NUM>) is transportable,
- a sorting apparatus (<NUM>/<NUM>/<NUM>) is provided, which allows for picking up an individual object A or B or C (...) or a group of individual objects from any of the trays (<NUM>) and any of the pallets (<NUM>, <NUM>,...) respectively,
wherein the sorting apparatus (<NUM>/<NUM>/<NUM>) comprises two or three mechanisms:
a. A mechanism (<NUM>, <NUM>, <NUM>) that is adapted to lift up the tray(s) (<NUM>) from the source tray in which the object(s) (A, B, C,...) is/are located,
b. A mechanism (<NUM>, <NUM>, <NUM>) that is adapted to lift up any/all pallets (<NUM>, <NUM>,...) inside the source tray, from the pallet (<NUM>,...) on which the object (A, B, C,...) is located
c. A mechanism (<NUM>, <NUM>, <NUM>) adapted to pick up and transfer the object (A, B, C,...) from the source pallet to a target tray (<NUM>) which is either part of the stack of trays or a separate tray
wherein in the case of two mechanisms mechanism "a." and mechanism "b." are the same mechanism and
wherein the mechanism a and b are provided as adjacent multiples n with an any natural number of greater or equal to <NUM> with a single or a number of adjacent mechanism(s) c that is lower than the number of mechanisms a and/or b but is at least <NUM>.