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 storage space may comprise a cavity arranged centrally within the vehicle body 201a as shown in <FIG> and as described in e.g. <CIT>, the contents of which are incorporated herein by reference.

Such a vehicle is described in detail in e.g. NO317366, the contents of which are also incorporated herein by reference.

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 contents of which are incorporated herein by reference. 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.

<CIT> describes a storage system including a charging station assembly for charging a plurality of power sources and a method thereof. The charging station assembly includes a charging station support fixing the charging station assembly to a base of the storage system, a plurality of charging stations, each charging station including a charger that charges the plurality of power sources and a power source transport device enabling relocation of the power source between an operational position on a remotely operated vehicle and a charging position in or at any one of the plurality of charging stations.

<CIT> describes a station for charging, battery swapping and energy storage comprising: a battery swapping device configured to replace a battery for an electric vehicle; a quick-swap battery pack for storing electric energy; a charging and discharging device configured to charge the quick-swap battery pack by a power grid and discharging the quick-swap battery pack to the power grid; and a monitoring system for monitoring an overall operating condition of the station and power consumption peaks and valleys of the power grid as well as controlling the battery swapping device to replace the quick-swap battery pack and controlling the charging or discharging of the charging and discharging device.

<CIT> describes a charging system for simultaneously charging the batteries of a plurality of battery powered vehicles. The charging includes one or more DC-DC power converters having one or more charging ports configured to plug into the batteries. The DC-DC power converters are each configured to selectively connect to more than one charging port to selectively provide for higher port power levels. The DC-DC power converters connect to an AC rectifier through a DC bus. The AC rectifier connects to an AC power source having a limited power rating. The AC charging system also has a controller that controls the operation of the DC-DC power converters such that the total power draw on the AC rectifier does not exceed the power rating. The system is further configured such that the DC-DC power converters can drain selected batteries to obtain power for charging other batteries, thus allowing for batteries to be cycled.

<CIT> describes a battery exchange station and a method of operating the battery exchange station. The battery exchange station and the method of operating the battery exchange station allow for utilization of electricity stored in a battery and improve a system's operation and electricity demand conditions by charging a large-capacity battery with electricity coming from the system and providing the electricity stored in the large-capacity battery to the system. <CIT> describes a charging system for electric vehicles. The charging system comprises a grid power stage comprising an AC/DC inverter that can be connected on an input side via a connection point to an alternating current grid, a control device for monitoring a charging process, and at least one charging connection on an output side, the latter being able to be temporarily connected to a vehicle battery. A characteristic of the invention is that a buffer battery having a significantly higher charge capacity than the vehicle battery is connected to the grid charging stage. A rapid charging stage comprising the control device and a DC/DC inverter that can be temporarily connected to a vehicle battery on the output side by means of the charging connection is connected to the buffer battery. The buffer battery can further be connected to a charging location on the alternating current grid on the output side by means of a backcharging stage comprising a switching unit and a DC/AC inverter.

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 grid <NUM>, the content of each storage container <NUM>; and the movement of the container handling vehicles <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> colliding with each other, the automated storage and retrieval system <NUM> comprises a control system which typically is computerized and which typically comprises a database for keeping track of the storage containers <NUM>.

In addition to installation, the biggest cost in operating an automated storage system, is the cost of the energy consumed by the container handling vehicles in their daily operations. It is therefore an object of the present invention to reduce this cost.

The present invention relates to a system for power management of an automated storage and retrieval system comprising a plurality of container handling vehicles with at least one exchangeable and rechargeable power source for handling containers in a three dimensional underlying storage grid, a charging device for charging or drawing power from the at least one exchangeable and rechargeable power source, a power source for supplying power to the automated storage and retrieval system, and the charging device a monitoring system for monitoring energy prices, a power manager, wherein said monitoring system is configured to continuously update a the power manager with energy prices, and the power manager is configured to be updated with information regarding the level of charge of the rechargeable power sources and current resources in terms of the capacity and usage requirements of the container handling vehicles, and said power manager is configured to adjust a power strategy of the automated storage and retrieval system according to the energy prices and to control the stored energy from the rechargeable power sources via the charging devices as an additional power source for the automated storage and retrieval system during periods of high energy cost. Further the power manager is configured to control charging of the rechargeable power source(s) during periods of low energy cost and to control the stored energy as an additional power source for the storage system during periods of high energy cost and to use a ranking system to decide in which order to charge two or more rechargeable power sources and to control storing of energy. The monitoring system monitors present and upcoming energy prices.

Also, the power source can receive power via locally generated energy from renewable energy sources and/or grid power.

The ranking system of the power manager is configured to decide to charge the rechargeable power sources with the highest charging level first and to decide to use the rechargeable power sources with the highest charging level as an additional power source first.

The charging device can be a charging station or a charging robot, and at least one large capacity battery can be used for storing energy during periods of low energy cost.

The present invention relates toa method for power management of an automated storage and retrieval system comprising: a plurality of container handling vehicles, with at least one exchangeable and rechargeable power source for handling containers in a three-dimensional underlying storage grid, a charging device for charging or drawing power from the at least one exchangeable and rechargeable power source, a power source for supplying power to the automated storage and retrieval system, and the charging device a monitoring system for monitoring energy prices, a power manager,, the method comprises the following steps: letting the monitoring system establish external power information by: reading present power consumption, and updating present and upcoming energy cost,letting the monitoring system establish internal power information by: acquiring the current energy state of the automated storage and retrieval system, and estimating the future energy state of the automated storage and retrieval system, letting the power manager update the power strategy of the system according to the external and internal power information, letting the power manager control use of stored energy from the rechargeable power sources via the charging devices as an additional power source for the automated storage and retrieval system during periods of high energy cost.

The power strategy of the system may be updated by letting the power manager use a ranking system to decide in which order to charge the rechargeable power sources and/or letting the ranking system of the power manager decide to charge the rechargeable power sources with the highest charging level first and/or letting the ranking system of the power manager decide to use the rechargeable power sources with the highest charging level as an additional power source first.

By letting a power manager control the charging of the rechargeable power sources dependent on the prices of power it is possible to reduce the cost of power in a storage system. The rechargeable power sources may be used as an additional power source for the system when the prices are high. This additional power source allows the storage system to store power when prices are low and use the stored power when prices are high. By incorporating a power manager that controls the flow of power to or from the rechargeable power sources, the cost of operating the storage system can be reduced greatly and the problem with the operation cost of an automated storage system can be solved.

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

In the following, the invention will be discussed in more detail with reference to the appended drawings. It should be understood, however, that the drawings are not intended to limit the invention to the subject-matter depicted.

A typical prior art automated storage and retrieval system <NUM> with a framework structure <NUM> was described in the background section above.

The container handling vehicle rail system <NUM> allows the container handling vehicles <NUM> to move horizontally between different grid locations, where each grid location is associated with a grid cell <NUM>.

In <FIG>, the storage grid <NUM> is shown with a height of eight grid cells <NUM>. It is understood, however, that the storage grid <NUM> can in principle be of any size. The storage grid <NUM> can be considerably wider and/or longer than disclosed in <FIG>. For example, the grid <NUM> may have a horizontal extent of more than 700x700 storage columns <NUM>. Also, the grid <NUM> can be considerably deeper than disclosed in <FIG>. For example, the storage grid <NUM> may be more than twelve grid cells <NUM> deep, i.e. in the Z direction indicated in <FIG>.

<FIG> is a perspective view of a prior art container handling vehicle having a centrally arranged cavity for containing storage containers <NUM> therein.

The central cavity container handling vehicles <NUM> 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 contents of which are incorporated herein by reference.

<FIG> is a perspective view of a prior art container handling vehicle having a cantilever for containing storage containers <NUM> underneath.

<FIG> is a box drawing of the different modules of the present invention and how they are connected. The storage system receives power from at least one power source <NUM>. The power source <NUM> can be either grid power or locally generated power from renewable power sources. Power can further be stored in rechargeable power sources comprised in the system. In a preferred embodiment the storage system <NUM> receives both grid power and locally generated power from renewable power sources. Locally generated power from renewable power sources can be wind power, hydro power, solar power or any other power source that is available. The amount of available power and the cost of the power is monitored by a monitoring system <NUM>. The monitoring system <NUM> can receive power information about available power and current cost of power from the grid provider, as well as an estimate of costs of power for an upcoming time period. The upcoming time period may for instance be the next <NUM> hours or even further ahead in time.

The monitoring system <NUM> sends the power information to a power manager <NUM>. The power manager <NUM> controls how the power required for the operation of the system is distributed and how much power should be drawn from the grid power, how much should be drawn from the locally generated power from renewable power sources and/or how much power should be drawn from the power stored in rechargeable power sources of the system. The power manager also controls if grid power or power from renewable power sources should be used for charging the rechargeable power sources.

The power manager <NUM> is in control of at least one charging device <NUM>, The charging device <NUM> is used to charge at least one rechargeable power source <NUM>. In a preferred solution there is a plurality of rechargeable power sources <NUM> stored at a plurality of different charging devices <NUM>. These rechargeable power sources <NUM> can be batteries used for powering the container handling vehicles <NUM>, <NUM>. Alternatively, or additionally, the rechargeable power sources <NUM> can be battery packs, whose sole purpose is to store energy when the conditions are right for the locally generated renewable power sources to produce a surplus of energy and when the prices for grid power are low.

The charging device <NUM> can both charge the rechargeable power sources <NUM> and draw power from the rechargeable power sources <NUM>. The power is directed to the charging devices <NUM> from either the power grid and/or the locally renewable power sources. The power manager <NUM> can control the distribution of the power e.g. that some energy is stored for later use, some energy is used for charging rechargeable power sources <NUM> of the container handling vehicles <NUM>, <NUM> and some energy is used to operate the rest of the system.

The stored power can be directed from the rechargeable power sources <NUM> via the charging devices <NUM> to power the rest of the storage system.

<FIG> is a flow chart showing the different steps of the method according to a preferred embodiment of the present invention.

In this embodiment the storage system first retrieves external power information <NUM>. This requires retrieving information of the current energy supply <NUM> and updating the estimate for the future cost of energy <NUM>.

For obtaining information regarding the current energy supply <NUM>, the first step is to check if there is locally generated renewable energy available <NUM>. The amount of available energy from a locally generated energy source is retrieved <NUM>. The next step is to retrieve information of the prices for grid power <NUM>. This can be obtained via e.g. downloading information from the internet.

The next step is to estimate future energy cost <NUM>. If the system is connected to a locally generated renewable energy source <NUM> the future energy production from this source is estimated <NUM>. This is done by collecting information like weather data, time of day and which season it is in order to estimate the available amount of future energy from the locally generated renewable energy source. Further, the predicted prices for the future grid energy is retrieved and updated <NUM>.

The next step is to retrieve internal power information <NUM>.

Retrieving the internal power information <NUM> comprises the step of calculating the systems current energy state <NUM>. The current energy state can comprise information regarding how much energy that is stored in the system at the current time. Information regarding the current energy consumption of the system is also retrieved. The current consumption depends on how many container handling vehicles are operating, how many rechargeable power sources are charging in the charging devices and how much energy is consumed by the rest of the system, e.g. by the ports, conveyer belts and such.

Retrieving the internal power information also involves the step of updating the estimate for the systems future energy state <NUM>. This comprises estimation of the energy need for the current and upcoming activities. Further the historical data can be used in order to improve the estimates. The historical data can be used in machine learning and in artificial intelligence in order to improve the accuracy of the estimated future power consumption.

The final step is to update the power strategy <NUM>. The updating of the power strategy <NUM> involves a first step <NUM> of updating the retrieved power information, both internal <NUM> and external <NUM>, and the energy need, and using historical data to optimize the charging strategy of the power manager <NUM>.

Updating the power strategy finally involves planning the future energy state of the system <NUM>. If the cost of energy is low, or there is high production of locally generated renewable energy, the power manager will try to increase the stored energy in the system by charging the rechargeable energy sources more often and for a longer period of time. This is planned in relation to the activity of the system where any reduction to operational efficiency is also minimised.

When all steps are done the power manager <NUM> starts the process over again and the power manager is hence updated continuously by receiving or retrieving information about the energy prices, charging status of the rechargeable power sources, and the internal and external power information.

In an alternative embodiment of the present invention the charging strategy can be set statically. The batteries can be set to charge at fixed time intervals during the day. Instead of collecting estimated future energy cost, the system can be set up with fixed time intervals wherein it is preferred that the storage system increases its state of charge. This will typically be favorable for businesses with a work shift where the charging of the system is set to a time of day when the energy price is at its lowest (typically evening time or night time). Another time of day when the system can be set to increase its state of charge is during lunch time. Basically, any time when the ordinary work force has a down time, it is a good time for increasing the state of charge.

Claim 1:
A system for power management of an automated storage and retrieval system (<NUM>) comprising a plurality of container handling vehicles (<NUM>, <NUM>) with at least one exchangeable and rechargeable power source (<NUM>) for handling containers in a three dimensional underlying storage grid (<NUM>),
a charging device (<NUM>) for charging or drawing power from the at least one exchangeable and rechargeable power source (<NUM>),
a power source (<NUM>) for supplying power to the automated storage and retrieval system (<NUM>) and to the charging device (<NUM>),
a monitoring system (<NUM>) for monitoring energy prices, and
a power manager (<NUM>), characterized in that:
said monitoring system (<NUM>) is configured to continuously update the power manager (<NUM>) with energy prices, and
the power manager (<NUM>) is configured to adjust a power strategy of the automated storage and retrieval system (<NUM>) according to the energy prices and to be updated with information regarding the level of charge of the at least one exchangeable and rechargeable power source (<NUM>) and current resources in terms of the capacity and usage requirements of the container handling vehicles (<NUM>, <NUM>),
and said power manager (<NUM>) is configured to control the stored energy from the at least one exchangeable and rechargeable power source (<NUM>) via the charging device (<NUM>) as an additional power source for the automated storage and retrieval system (<NUM>) during periods of high energy cost.