Patent Description:
<FIG> disclose a typical prior art automated storage and retrieval system <NUM> with a framework structure <NUM>. <FIG> disclose a prior art container handling vehicle <NUM> operating the system <NUM> disclosed in <FIG>, respectively.

The framework structure <NUM> comprises a plurality of upright members <NUM> and optionally a plurality of horizontal members <NUM> supporting the upright members <NUM>.

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>.

Each storage container <NUM> may typically hold a plurality of product items (not shown), and the product items within a storage container <NUM> may be identical, or may be of different product types depending on the application.

The storage grid <NUM> guards against horizontal movement of the storage containers <NUM> in the stacks <NUM>, and guides vertical movement of the storage containers <NUM>, but does normally not otherwise support the storage containers <NUM> when stacked.

The automated storage and retrieval system <NUM> comprises a container handling vehicle 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> (as exemplified in <FIG>) are 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 horizontal extent of one of the grid cells <NUM> constituting the grid pattern is in <FIG> marked by thick lines.

Each grid cell <NUM> has a width which is typically within the interval of <NUM> to <NUM>, and a length which is typically within the interval of <NUM> to <NUM>. Each grid opening <NUM> has a width and a length which is typically <NUM> to <NUM> less than the width and the length of the grid cell <NUM> due to the horizontal extent of the rails <NUM>,<NUM>.

In this way, the rail system <NUM> defines grid columns 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 and a wheel arrangement of eight wheels <NUM>,<NUM> where a first set of four wheels enable the lateral movement of the container handling vehicles <NUM>,<NUM> in the X direction and a second set of the remaining four wheels enable the lateral movement in the Y direction. One or both sets of wheels in the wheel arrangement can be lifted and lowered, so that the first set of wheels and/or the second set of wheels 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.

Conventionally, and also for the purpose of this application, Z=<NUM> identifies the uppermost layer of the grid <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 grid <NUM> disclosed in <FIG>, Z=<NUM> identifies the lowermost, bottom layer of the grid <NUM>. Consequently, as an example, and using the Cartesian coordinate system X, Y, Z indicated in <FIG>, the storage container identified as <NUM>' in <FIG> can be said to occupy grid location or cell X=<NUM>, Y=<NUM>, Z=<NUM>. The container handling vehicles <NUM> can be said to travel in layer Z=<NUM> and each grid column can be identified by its X and Y coordinates.

Each container handling vehicle <NUM> comprises a storage compartment or space (not shown) 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, e.g. as is described in <CIT>.

Alternatively, the container handling vehicles <NUM> may have a cantilever construction, as is described in NO317366.

The container handling vehicles <NUM> may have a footprint, i.e. an extent in the X and Y directions, which is generally equal to the lateral extent of a grid cell <NUM>, i.e. the extent of a grid cell <NUM> in the X and Y directions, e.g. as is described in <CIT> The term "lateral" used herein may mean "horizontal".

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

The rail system <NUM> may be a single track system, as is shown in <FIG>.

Alternatively, the rail system <NUM> may be a double track system, as is shown in <FIG>, thus allowing a container handling vehicle <NUM> having a footprint <NUM>,<NUM>' generally corresponding to the lateral area defined by a grid column <NUM> to travel along a row of grid columns even if another container handling vehicle <NUM> is positioned above a grid column neighboring that row. Both the single and double track system, or a combination comprising a single and double track arrangement in a single rail system <NUM>, forms a grid pattern in the horizontal plane P comprising a plurality of rectangular and uniform grid locations or grid cells <NUM>, where each grid cell <NUM> comprises a grid opening <NUM> being delimited by a pair of rails 110a,110b of the first rails <NUM> and a pair of rails 111a, 111b of the second set of rails <NUM>. In <FIG> the grid cell <NUM> is indicated by a dashed box.

Consequently, rails 110a and 110b form pairs of neighboring rails defining parallel rows of grid cells running in the X direction, and rails 111a and 111b form pairs of neighboring rails defining parallel rows of grid cells running in the Y direction.

As shown in <FIG>, each grid cell <NUM> has a width Wc which is typically within the interval of <NUM> to <NUM>, and a length Lc which is typically within the interval of <NUM> to <NUM>. Each grid opening <NUM> has a width Wo and a length Lo which is typically <NUM> to <NUM> less than the width Wc and the length Lc of the grid cell <NUM>.

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

In a storage grid <NUM>, a majority of the grid columns 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 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 a second location (not shown in the prior art figures) 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 in which the port is located may be referred to as a "delivery column" <NUM>,<NUM>. The drop-off and pick-up ports of the container handling vehicles are referred to as the "upper ports of a delivery column" <NUM>,<NUM>. While the opposite end of the delivery column is referred to as the "lower ports of a delivery column".

The storage grids <NUM> in <FIG> comprise two delivery columns <NUM> and <NUM>. The first delivery column <NUM> may for example comprise a dedicated drop-off port where the container handling vehicles <NUM>,<NUM> can drop off storage containers <NUM> to be transported through the delivery column <NUM> and further to an access or a transfer station (not shown in the prior art figures), and the second delivery column <NUM> may comprise a dedicated pick-up port where the container handling vehicles <NUM>,<NUM> can pick up storage containers <NUM> that have been transported through the delivery column <NUM> from an access or a transfer station. Each of the ports of the first and second delivery column <NUM>,<NUM> may comprise a port suitable for both pick up and drop of storage containers <NUM>.

The second location may typically be an access, picking or a stocking station where product items are removed from or positioned into the storage containers <NUM>. In an access, picking or a stocking station, the storage containers <NUM> are normally never removed from the automated storage and retrieval system <NUM>, but are returned into the storage grid <NUM> once accessed. For transfer of storage containers out or into the storage grid <NUM>, there are also lower ports provided in a delivery column, such lower ports are e.g. for transferring storage containers <NUM> to another storage facility (e.g. to another storage grid), directly to a transport vehicle (e.g. a train or a lorry), or to a production facility.

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 storage 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 (not shown) which typically is computerized and which typically comprises a database for keeping track of the storage containers <NUM>.

As previously mentioned, storage containers are typically brought via delivery columns <NUM>,<NUM> to and from an access station.

In order to efficiently pick goods from storage containers, it is known to provide an access station with a conveyor passing storage containers from delivery columns and through a picking zone. To facilitate ergonomic picking for persons working at the picking zone, it is known from the prior art to have a tilted conveyor at the picking zone where a picking person is working. An example of such prior art is disclosed in <CIT>, where a permanently tilted conveyor is arranged in the picking zone of a picking person, and tilting devices are provided on each side of the picking zone to tilt storage containers into or from a tilted position before and after they pass said picking zone. <CIT> comprises a conveyor line with a long straight portion passing through a picking zone, which aims to avoid the containers being slowed down in the picking zone. Therefore, the tilting of the containers in <CIT> is provided such that the picking person can see the contents of a container in advance of it arriving at the picking zone. A drawback to the solution in <CIT> is that it requires a wide area to locate the long straight portion of the conveyor line, which is cumbersome to install and takes up valuable space which is often limited in storage housing.

<CIT> describes a picking/supply station assembly for a storage system, the storage system comprising a grid structure of storage cells having a top level, each storage cell being arranged to accommodate a vertical stack of storage bins, at least one vehicle arranged to move horizontally at the top level of the grid structure and able to retrieve a storage bin from a storage cell at the top level of the grid structure and to deliver the storage bin to the picking/supply station assembly, wherein the picking/supply station assembly comprises a first bin lift device, a second bin lift device and a picking/supply station, wherein the first bin lift device is arrangeable to receive a storage bin from the at least one vehicle at the top level of the grid structure and deliver the storage bin to the picking/supply station; the picking/supply station comprises a bin transport assembly arranged to move the storage bin from the first bin lift device to the second bin lift device; and the second bin lift device is arranged to receive the storage bin from the bin transport assembly and is arrangeable to convey the storage bin to the top level of the grid structure. <CIT> describes a picking/supply station assembly and storage bins. A picking/supply station of the picking/supply station assembly comprises a work surface having an opening. The picking/supply station comprises a bin transport assembly comprising a conveyor system comprising multiple conveyor units arranged to transport the storage bins from a first bin lift device to the opening to a second bin lift device. A conveyor unit of the multiple conveyor units which is arranged below the opening is inclined. The picking/supply station comprises sidewalls enclosing the bin transport assembly, and comprises the work surface arranged above the bin transport assembly.

In view of the above, it is desirable to provide an access station, and an automated storage and retrieval system comprising such an access station that solves or at least mitigates one or more of the aforementioned problems related to the use of prior art access stations.

The invention is set forth in the independent claims and the dependent claims describe alternatives of the invention.

The invention provides in a first aspect an access station for picking storage containers, comprising:.

Thus, the access station according to the first aspect provides a solution which is flexible, as it may be operated both with a picking person or a robotic picker. Accordingly, the tilting device may on the one hand tilt a storage container in the picking zone when the access station is to be operated with a picking person, thereby providing the ergonomic benefits of tilting. On the other hand, the tilting device may not tilt storage containers when the access station is to be operated with a robotic picker, thereby allowing a more efficient throughput of storage containers. As robotic picking is only starting to come into use, and certain storage goods are more suited for robotic picking than others, this inventive access station provides a solution which gives optimal efficiency with a robotic picker whilst also allowing for use with a picking person.

Preferably, the tilting device may comprise a tiltable conveyor. However, in some configurations, the tilting device may comprise a platform, frame or rods adapted to tilt a conveyor independent of a conveyor.

Typically, the access station may be covered on its exterior by protective panels, except for:.

However, it is apparent that the entry position and the exit position may be interchangeable, depending on the direction of transport of the storage containers which is determined by the access station's conveyor(s) and external conditions.

The tilting angle range of the tilting device is from <NUM>° to <NUM>° relative to the pivot axis relative to the horizontal plane, more preferably from <NUM>° to <NUM>°, even more preferably from <NUM>° to <NUM>°, even more preferably from <NUM>° to <NUM>°, even more preferably from <NUM>° to <NUM>°, even more preferably from <NUM>° to <NUM>°, even more preferably from <NUM>° to <NUM>°, even more preferably from <NUM>° to <NUM>°, for example <NUM>°. The tilting device being arranged in the picking zone is thus advantageous as its angle may be adjusted according to the specific needs of a picking person, and the height of the access station from the ground.

The entry position and the exit position may be arranged for connection to at least one storage system conveyor. A storage system conveyor may typically be arranged below a rail system of an automated storage and retrieval system, such that container handling vehicles operating on the rail system may deliver storage containers to the storage system conveyor. The entry position may be connected to a storage system conveyor onto which storage containers are deposited by container handling vehicles, and the exit position may be connected to a storage system conveyor from where storage containers are retrieved by container handling vehicles. In some configurations, the entry position and the exit position may be connected each to a storage system conveyor, where the storage system conveyors are made up of at least one relay module - where storage containers may be deposited and retrieved by storage containers at one location in the relay module.

The access station may comprise only one tilting device arranged to tilt at least one storage container in the picking zone. The tilting device may be arranged to tilt a plurality of storage containers, thereby increasing throughput as storage containers are not delayed by a tilting process in the picking zone but enter the picking zone in an already tilted position.

The picking zone may be arranged to receive only one storage container. Typically, the picking zone may be arranged in an aperture of an access station, the access station being covered with panels except for the picking zone and the entry and exit positions. With only one storage container in the picking zone at a time, a picking person is less likely to be confused as to which storage container he/she should pick from. This problem is less likely to occur with a robotic picker, and an access station to be operated by a robotic picker may therefore be arranged with a picking zone arranged to receive a plurality of storage containers, for example by removing the top panels of an access station to uncover all storage containers within.

The tilting device may be arranged to tilt only one storage container. This may be advantageous for access station without panels, as it will be apparent to the picking person that only the tilted container should be picked from.

The access station may comprise three tilting devices. The three tilting devices may be arranged consecutively and adjacent each other along a front side of the access station. Each tilting device may comprise or form part of a conveyor to transport storage containers. Advantageously, the three tilting devices may each tilt one conveyor. Thus, a centre conveyor may be arranged in a tilted position when the access station is operated with a picking person, and the two lateral conveyors to each side tilt a storage container into and back out of a tilted position respectively upstream and downstream of the centre conveyor. As storage containers are not tilted in the picking zone, there is no delay as a storage container is brought into the picking zone, and this configuration may provide a more efficient access station. However, should the access station be operated by a robotic picker, all three tiltable conveyors can be arranged in a horizontal position, thereby increasing picking efficiency and speed due to the removal of time spent on tilting storage containers.

The access station may comprise an entry conveyor arranged to transport storage containers from the entry position to at least one access conveyor, and an exit conveyor may be arranged to transport storage containers from the at least one access conveyor to the exit position.

A transport direction of the entry conveyor may be parallel and opposite to a transport direction of the exit conveyor, and wherein a transport direction of the at least one access conveyor may be orthogonal to the transport directions of the entry and exit conveyors. Thus, the access station may have a relatively small width, substantially corresponding to three grid cells, with a U-shaped path of the storage containers and therefore requires less space than prior art solution. Furthermore, the access station may be more compatible with automated storage and retrieval systems which comprise two parallel storage system conveyors spaced at a distance of one grid cell to which the access station may be easily fitted.

The tilting device(s) may be arranged to tilt around an axis parallel to a transport direction of the at least one access conveyor. Thus, the tilting device may preferably tilt towards a front side of the access station, where a picking person may typically be located for picking from the storage containers.

The picking zone may be arranged towards a front side of the access station, and the access station may be arranged to receive an order container conveyor between the picking zone and a back side of the access station. In some configurations, an order container conveyor may be arranged to a side of the access station.

The invention relates to a method for operating an access station according to the first aspect, wherein the method comprises the steps of:.

Depending on the configuration of the tilting device, the step of tilting the storage container with a tilting device may be performed when the storage container is in the picking zone, or it may be performed before the storage container is in the picking zone.

The invention may relate to a further method for operating an access station according to the first aspect comprising the steps of:.

The method may also comprise the step of tilting a centre access conveyor in the picking zone, such that it is ready to receive a tilted storage container.

The access station also comprises protective paneling to shield a picking person from injury if he/she should try to reach inside the access station. The protective paneling comprises an aperture with a sliding door in the picking zone, thereby only allowing the picking person to see one storage container at a time which minimizes the risk of picking errors.

The invention further relates to an automated storage and retrieval system, the automated storage and retrieval system comprising:.

The system may comprise two storage system conveyors, a first storage system conveyor may be arranged to transport storage containers from the transfer position below the at least one delivery column to an entry position of the access station, and a second storage system conveyor may be arranged to transport storage containers from the exit position of the access station to the transfer position below the at least one delivery column.

The conveyors used in the access station according to any of the aforementioned aspects may comprise rolls with and/or without integrated motors. Typically, one conveyor roll comprises an integrated motor and is connected by at least one band to the remaining rolls for driving these. Different kinds of conveyors may be used which also allow the movement of storage containers perpendicular to the transport direction of the conveyors such as conveyor belts, wheels, balls.

In the following description, numerous specific details are introduced by way of example only to provide a thorough understanding of embodiments of the claimed device, system and method. In other instances, well-known structures or operations are not shown, or are not described in detail, to avoid obscuring aspects of the disclosed embodiments.

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

In the drawings, like reference numerals have been used to indicate like parts, elements or features unless otherwise explicitly stated or implicitly understood from the context.

<FIG> is a perspective view illustrating a front end <NUM> of an access station <NUM>, where the front end <NUM> may be defined as where a picking person or a robotic picker <NUM> (not shown in <FIG>) is intended to pick articles from the storage containers <NUM> passing through the access station <NUM>. The articles are picked at a picking zone <NUM> which is illustrated by the dashed circle at the front end <NUM> of the access station, the back end <NUM> is not visible in <FIG>. The access station <NUM> comprises top panels <NUM>,<NUM>', front panels <NUM>,<NUM>' and side panels <NUM>,<NUM>' forming an outer housing and covering the inner mechanisms. The panels <NUM>,<NUM>,<NUM> prevent injuries to a picking person or human operator trying to reach inside the housing, as the panels <NUM>,<NUM>,<NUM> shield the inner mechanisms. The top panel <NUM> is arranged to accommodate an order container conveyor <NUM> which may pass over said top panel <NUM>, such that goods may be picked from a storage container <NUM> in the picking zone <NUM> and placed on the storage goods conveyor and vice versa.

In the embodiment of <FIG>, the back end <NUM> may be without panels so as to allow the entry and exit of storage containers <NUM> to the access station <NUM> through the back end <NUM>. The picking zone <NUM> is illustrated as comprising an aperture in a tilted top panel <NUM>' with a closed sliding door <NUM>. In an open position, the sliding door <NUM> uncovers the entire top area of one storage container <NUM> such that its contents may be viewed, accessed and picked. According to the embodiment of <FIG>, a storage container <NUM> can only be picked when it is located beneath the sliding door <NUM> in an open position, and as such the sliding door <NUM> may define the picking zone <NUM>. The sliding door <NUM> ensures that only the storage container <NUM> located in the picking zone <NUM> can be picked when the sliding door <NUM> is open, thus avoiding risk of injury from a picking person reaching into the access station <NUM>. The sliding door <NUM> may ensure that only one storage container <NUM> is accessible at a time, thereby minimizing confusion for the picking person regarding which storage container <NUM> is to be picked from, in contrast to the prior art where a series of storage containers <NUM> openly pass by the picking zone. The panels <NUM>,<NUM>,<NUM> and sliding door <NUM> may not be necessary for embodiments not according to the invention configured with a robotic picker <NUM> which is less prone to injury from reaching inside the access station <NUM>.

As previously mentioned, the back end <NUM> comprises an entry position <NUM> and an exit position <NUM> arranged to respectively receive and deliver storage containers <NUM> to and from the access station <NUM>. However, in other embodiments of the invention, not illustrated herein, the entry position <NUM> and exit position <NUM> may be arranged at other locations, for example to the sides of the access station <NUM>.

The access station <NUM> illustrated in <FIG> is exemplified as transporting storage containers <NUM> in the direction represented by arrows <NUM>,<NUM>,<NUM>. Thus, storage containers <NUM> are transported from an entry position <NUM> where they are in a horizontal position towards the front end <NUM> of the access station <NUM>, represented by arrow <NUM>. At the front end <NUM> of the access station <NUM> the direction of movement changes to transport storage containers <NUM> along the front end <NUM>, represented by arrows <NUM>, and thereby past the picking zone <NUM>. The storage containers <NUM> can be brought from a horizontal position to a tilted position whilst at the front end <NUM> of the access station <NUM>, such that the storage containers <NUM> may be in a tilted position in the picking zone <NUM>. The ability to tilt the storage container <NUM> allows a picking person to view and/or access the articles within the storage container <NUM> more easily.

The tilting angle range is from <NUM>° to <NUM>° around a pivot axis extending along the front end <NUM> of the access station <NUM> and relative to the horizontal plane. The tilting angle should not exceed a maximum tilting angle that would represent a significant risk of stored items / articles tipping out of the storage container in question. This maximum allowed tilting angle depends on the amount and size of items / articles within the storage container. A storage container <NUM> being filled with items up to its upper rim will have a lower maximum tilting range that a storage container <NUM> having items filling the containers' <NUM> vertical height only partly. Accordingly, the tilting angle range may typically be for example be from <NUM>° to <NUM>°, for example <NUM>°. The tilting angle may be adjustable according to the height of the access station from the floor, and the height of the picking person. The tilting angle may therefore be set to an optimal angle for picking for a certain picking person. The exterior housing comprising the panels <NUM>,<NUM>,<NUM> may likewise be adapted to the tilting angle range. For example, the exterior housing in a certain embodiment may be arranged for a maximum tilting angle such that storage containers <NUM> may be tilted at any smaller angle.

A control panel <NUM> is arranged on the front panel <NUM> of the access station <NUM>. The control panel <NUM> may be configured to set specifications for controlling picking operations such as the speed of transport for storage containers <NUM> through the access station <NUM>, reversal of the transport direction, opening and closing of the sliding door <NUM>, whether to tilt storage containers <NUM> passing through, tilting of only one storage container <NUM> being in the picking zone <NUM>, the tilting angle of the storage containers <NUM> and/or emergency stop functions. The control panel <NUM> may also have a user interface, such as a screen or display configured to display the specifications of the access station <NUM>, the weight of a certain storage container <NUM> and its content and/or the identification number of a certain storage container <NUM>. If the access station <NUM> is to be used with a robotic picker <NUM>, the control panel <NUM> may also be connected with the robotic picker <NUM> to synchronize their operations.

For the first aspect of the invention where storage containers <NUM> may be tilted in the picking zone <NUM>, as in <FIG> and <FIG>, the access station <NUM> is more suited to be used by either a picking person and/or a robotic picker <NUM>. Tilting of storage containers <NUM> is advantageous when a picking person uses the access station <NUM>, however, the tilting operation inevitably causes lag in the flow of storage containers <NUM> flowing through an access station <NUM>. According to the first aspect illustrated in <FIG> and <FIG>, tilting is optional and can be regulated with the control panel <NUM>.

Depending on whether a picking person or a robotic picker <NUM> is used to pick the storage containers <NUM> passing through the access station <NUM>, specifications for controlling the picking operation may be set by the control panel <NUM> which are suited to each particular use. As a robotic picker <NUM> may have a reach and visual angle which does not require tilting of the storage containers <NUM>, the specifications of the operation of the access station <NUM> may be set accordingly, i.e. tilting of storage containers <NUM> is not performed during routine picking operation. The sliding door <NUM> may also be kept in an open position when used with a robotic picker <NUM> as the robot <NUM> is not prone to harm from reaching into the access station <NUM> and getting stuck in machinery. However, should a human operator require visual inspection of the work of the robotic picker <NUM> or perform random checks of certain storage containers <NUM>, then the control panel <NUM> can be used to tilt one storage container <NUM> in the picking zone <NUM>, or a number of storage containers <NUM> passing by at set intervals.

<FIG> illustrate a front end <NUM> of an access station <NUM> in a perspective view according to the first aspect, where most of the exterior panels have been removed such that the frame and inner mechanisms are visible. The frame may be made from extruded aluminium profiles. Electric cabling may be arranged in or along the frameand panels of the access station for powering, measuring and controlling the different functionalities of the access station <NUM>.

In the exemplary embodiment of <FIG>, storage containers <NUM> are received at the back side <NUM> of the access station <NUM> at an entry position <NUM> located on an entry conveyor <NUM>. Typically, the entry position <NUM> is configured for connection to another conveyor, for example a storage system conveyor <NUM>,<NUM> which transports storage containers <NUM> to and from the entry position <NUM>, see <FIG>. Upon entering the access station <NUM>, the entry conveyor <NUM> transports the storage container <NUM> in a transport direction represented by the arrow <NUM> to a lateral access conveyor <NUM>. The entry conveyor <NUM> is exemplified as comprising two transport belts <NUM> driven by an electric motor <NUM>, but as will be apparent to the person skilled in the art, various types of conveyors may be employed.

The embodiment of <FIG> is further illustrated as comprising three access conveyors; two lateral access conveyors <NUM> for transporting storage containers <NUM> from and to the entry conveyor <NUM> and exit conveyor <NUM>, and one centre access conveyor <NUM> for transporting storage containers <NUM> between the two lateral access conveyors <NUM> on each side. The lateral access conveyors <NUM> are exemplified as comprising a plurality of roller conveyors <NUM> for transporting storage containers <NUM> along in an access conveyor direction, represented by the arrows <NUM>, along the direction of the front end <NUM> of the access station <NUM>. The roller conveyors <NUM> are mounted on a roller conveyor frame <NUM> which extends between the two transport belts <NUM> of the entry conveyor <NUM>, similarly for the exit conveyor <NUM>. Typically, one of the rollers in a roller conveyor <NUM> comprises an integrated driving motor (not shown), whilst the remaining rollers may be connected by belts (not shown) to the driving roller, or they may be passive. The lateral access conveyors <NUM> comprise a frame <NUM> comprising roller conveyors <NUM> and are displaceable by a lifting mechanism (not shown) such that a lateral access conveyor <NUM> can be lifted between a lower position and an upper position. Thus, a storage container <NUM> is transported in on the transport belts <NUM> of the entry conveyor <NUM>, and once in position over the roller conveyors <NUM> they are lifted up with the frame <NUM> (see <FIG>). With the lateral access conveyor <NUM> in an upper position, the storage container <NUM> will now rest on the lateral access conveyor <NUM> and can be transported along the front end <NUM> of the access station <NUM> in the direction of arrow <NUM>. At the overlaps between the entry conveyor <NUM>, exit conveyor <NUM> and the lateral access conveyors <NUM>, the direction of transport of the storage containers <NUM> therefore changes orthogonally.

Although the entry conveyor <NUM>, exit conveyor <NUM> and centre access conveyor <NUM> are exemplified as comprising transport belts <NUM>, and the lateral access conveyors <NUM> are exemplified as roller conveyors <NUM> in the configurations disclosed in <FIG> and <FIG>, it will be apparent to the person skilled in the art that a variety of other conveyors may be used such as rail mounted trolleys, belts or conveyor balls.

Though hidden from view by the storage container <NUM> in <FIG>, the centre access conveyor <NUM> comprises two transport belts <NUM>, similar to those of the entry conveyor <NUM> and the exit conveyor <NUM>. However, as will be apparent to the person skilled in the art, various types of conveyors may be employed for the centre access conveyor <NUM>.

The centre access conveyor <NUM> is located in the picking zone <NUM>, represented by the dashed circle, in <FIG>, and a storage container <NUM> is illustrated in a horizontal position on the centre access conveyor <NUM> in the picking zone <NUM>. When the access station <NUM> is used with a robotic picker <NUM>, the storage container <NUM> may be picked in a horizontal position as in <FIG>. The position of the storage container <NUM> in <FIG> may also be pre- or post-tilting, i.e. respectively upon arrival of the storage container <NUM> to the lateral access conveyor <NUM> before tilting and potential picking, and after the storage container <NUM> has been tilted back to a horizontal position before transport to the lateral access conveyor <NUM>, e.g., for a human picker.

In <FIG>, a storage container <NUM> is illustrated in a tilted position on the centre access conveyor <NUM> in the picking zone <NUM>. The storage container <NUM> may be brought to this position when it is to be accessed and/or viewed by a human operator, e.g. when the access station <NUM> is used with a picking person. However, the storage container <NUM> may also be picked by a robotic picker <NUM> in a tilted position. The centre access conveyor <NUM> is arranged to be tilted by a tilting device <NUM> (not visible in <FIG>) around a longitudinal direction parallel to the direction of transport <NUM> of the access conveyors <NUM>,<NUM>. The centre access conveyor <NUM> may therefore be hingedly connected to the frame of the access station <NUM> towards the front end <NUM>. As previously mentioned, the tilting device <NUM> is arranged to tilt the storage containers <NUM> in a tilting angle range from <NUM>° to <NUM>°, where the desired angle may be set by the control panel <NUM>.

In a horizontal position, the centre access conveyor <NUM> transfers the storage container <NUM> from the picking zone <NUM> to the lateral access conveyor <NUM> in the direction represented by arrow <NUM>, which is raised to an upper position to receive the storage container <NUM> above the transport belts <NUM> of the exit conveyor <NUM>. Once the storage container <NUM> is in the overlapping position of the lateral access conveyor <NUM> and the exit conveyor <NUM>, a frame <NUM> of the lateral access conveyor <NUM> is lifted down to a lower position such that the storage container <NUM> comes to rest on the belts of the exit conveyor <NUM>. Upon being supported on the transport belts <NUM> of the exit conveyor <NUM>, the storage container <NUM> can be transported in the direction represented by the arrow <NUM> to the exit position <NUM>, represented by the dashed circle, and delivered out of the access station <NUM>. The exit conveyor <NUM> may typically be configured for connection to another conveyor at the exit position <NUM>, for transporting the storage containers <NUM> away from the access station <NUM>.

The access station <NUM> may comprise adjustable feet <NUM>, exemplified in <FIG>, these adjustable feet <NUM> may be used to level the access station <NUM> on an uneven floor or to adjust the access station <NUM> to meet conveyors at the entry position <NUM> and the exit position <NUM>.

<FIG> illustrate the first aspect as in <FIG> respectively, where the back end <NUM> of the access station <NUM> is shown in a perspective view. No exterior panels have been stripped in the views of <FIG>, as the back end <NUM> of the access station <NUM> may typically be open to allow the entry and exit of storage containers <NUM>. Both the entry position <NUM> and the exit position <NUM> are visible in <FIG> illustrated on the entry conveyor <NUM> and the exit conveyor <NUM> respectively, showing the transport belts <NUM> and driving motors <NUM> of the said conveyors <NUM>,<NUM>. The driving motors may typically comprise electric motors. However, it is conceivable that the various electric motors of the access station <NUM> may be driven by motors with other power sources than electric, such as e.g. pneumatic pressure. The frame <NUM> for the roller conveyors of the lateral access conveyors <NUM> is also more clearly visible in <FIG>, and the transport belts <NUM> of the exit conveyor <NUM> can be seen passing by on each side of the roller conveyor frame <NUM>.

The lifting device <NUM> is shown in <FIG> in a horizontal position, and in <FIG> in a tilted position. Shown in the tilted position in <FIG>, the open top of a storage container <NUM> is brought up to the sliding door <NUM>. The lifting device <NUM> is powered by a tilting motor <NUM>, which drives a displacement belt connected to a sliding frame <NUM>. Hingedly connected to the sliding frame <NUM> are the ends of two rods <NUM>, where the opposite end of the rods <NUM> hingedly connected to a frame <NUM> which is rigidly connected to the centre access conveyor <NUM>. Thus, the tilting motor <NUM> drives the belt, which laterally displaces the sliding frame <NUM> and the rods <NUM> will accordingly move to tilt the centre access conveyor <NUM> around a hinged connection (not visible in <FIG>) provided at the front end <NUM> of the access station <NUM>.

As illustrated in <FIG> the centre access conveyor comprises a frame <NUM> provided with transport belts <NUM> for transport of storage containers <NUM>, where the belts <NUM> are driven by an electric motor <NUM>. The frame <NUM> of the centre access conveyor <NUM> may comprise a weighing mechanism, such as load cells arranged on the frame <NUM> (not shown). The load cells may be signally connected to the control panel <NUM>. As will be apparent, the centre access conveyor <NUM> may also comprise other kinds of conveyors such as roller conveyors <NUM>. In configurations where roller conveyors <NUM> are used for the centre access conveyor <NUM>, it is conceivable that the tilting device <NUM> comprises rods or a frame which can pass up between the rollers to tilt a storage container <NUM>.

<FIG> and <FIG> illustrate a second aspect of an access station <NUM>, comprising a distinct inner mechanism relative to the first aspect of <FIG>. Most notably, the second aspect comprises a permanently tilted centre access conveyor <NUM>, whilst the lateral access conveyors <NUM> are tiltable. Tilting the storage containers <NUM> before and after they enter the picking zone <NUM> may allow for faster transport of storage containers <NUM> through the access station. This is due to the simultaneous operations that are allowed when storage containers <NUM> are not tilted in the picking zone <NUM>; a storage container <NUM> in the picking zone <NUM> can be picked whilst an upstream storage container <NUM> is brought onto the lateral access conveyor <NUM> and tilted into a tilted position such that it is ready for transport to the picking zone <NUM>, and a downstream storage container <NUM> is tilted back to horizontal position and transported away with the exit conveyor <NUM>, upon which the tilting device <NUM> brings the lateral access conveyor <NUM> back to a tilted position to receive a picked storage container <NUM>.

The second aspect in <FIG> and <FIG> may comprise a similar frame and exterior housing to that of <FIG>. Thus, the access station <NUM> of <FIG> and <FIG> may take up substantially the same size as those illustrated in <FIG>.

<FIG> show an access station <NUM> stripped of plates in a perspective view from a corner of the front end <NUM>. <FIG> illustrates the access station <NUM> without storage containers <NUM> on the conveyors <NUM>,<NUM>,<NUM>,<NUM> and the transport and tilting mechanisms are therefore visible. As <FIG> illustrates, all the conveyors <NUM>,<NUM>,<NUM>,<NUM> in this configuration are exemplified as comprising transport belts <NUM>. However, many other kinds of conveyors may be employed in various different configurations.

<FIG> illustrates the entry position <NUM> on the entry conveyor <NUM> where storage containers <NUM> enter the access station <NUM>. Similarly to the conveyor configurations of <FIG> and <FIG>, the entry conveyor <NUM> is arranged to transport storage containers <NUM> from the entry position <NUM> up to the front end <NUM> of the access station <NUM> and over the lateral access conveyor <NUM>. The transport belts <NUM> of the entry conveyor <NUM> therefore pass on each side of the lateral access conveyor <NUM>. <FIG> illustrates the lateral access conveyor <NUM> in a horizontal position, where it is arranged below the entry conveyor <NUM> such that storage containers <NUM> can pass unhindered above on the entry conveyor <NUM>.

Forward guide rails <NUM> are arranged to guide storage containers <NUM> as they are transported along the front end <NUM> of the access station <NUM>, and these also hinder storage containers <NUM> from crashing into the inside frame or panels of the access station <NUM> as the storage containers <NUM> are transported by the entry conveyor <NUM>. Such forward guide rails <NUM> are also present in the configurations of <FIG>.

The lateral access conveyor <NUM> is arranged on a frame <NUM>, which frame also comprises a portion of the forward guide rail <NUM>. The frame <NUM> of the lateral access conveyor <NUM> is tiltable around a hinged connection. The lateral access conveyor <NUM> may thus be lifted above the entry conveyor <NUM>, such that storage containers <NUM> can change direction unhindered and be transported along the front end <NUM> of the access station <NUM>. A tilting device <NUM> (not visible in <FIG>) is hingedly connected to a back end of the frame <NUM> of the lateral access conveyor <NUM>.

The lateral access conveyor <NUM> illustrated in <FIG> and <FIG>, may be of a similar configuration to the centre access conveyor <NUM> illustrated in <FIG> comprising two transport belts <NUM>, although the frame <NUM> and tilting device <NUM> connected to said frame <NUM> may differ to constructional constraints.

<FIG> is a perspective view of the back end <NUM> of an access station <NUM> stripped of plates, according to the second aspect illustrated in <FIG>. Two storage containers <NUM> are shown in the access station <NUM>, one on the permanently tilted centre access conveyor <NUM> in the picking zone <NUM>, and the other on the lateral access conveyor <NUM> in a tilted position upstream of the picking zone <NUM>. The sliding door <NUM> is also included in <FIG>, illustrated in a closed position.

<FIG> illustrates in more detail the tilting device <NUM> of the lateral access conveyor <NUM>, which comprises a different configuration to that of the tilting device <NUM> of the centre access conveyor <NUM> in <FIG>. Due to space restrictions along the entry conveyor <NUM>, the tilting device <NUM> in <FIG> comprises a sliding frame <NUM> mounted vertically, in contrast to horizontally as shown in <FIG>. The feet of the access station <NUM> therefore also differ from the configuration in <FIG>, to accommodate for space for the sliding frame <NUM>. However, various different kinds of feet or platforms may be applied for an access station <NUM>, and the configuration of <FIG> and <FIG> could also be provided with adjustable feet. A drive motor <NUM> for tilting is shown below the entry conveyor <NUM>, which may drive a belt connected to the sliding frame <NUM> and thus move it up or down to tilt the lateral access conveyor <NUM>.

As will be apparent, many variations of tilting devices <NUM> and lifting mechanisms for the access conveyors <NUM>,<NUM> are conceivable. For example, the tilting device <NUM> illustrated in <FIG> for the lateral access conveyor <NUM> may also be used for the centre access conveyor <NUM> of the aspect in <FIG>.

Similarly to the access station of <FIG>, the access station of <FIG> and <FIG> may be symmetric from centre to both sides. The conveyors <NUM>,<NUM>,<NUM> on each side can perform the same functions as those on the other side, although to transport storage containers <NUM> in another direction. For example, the exit conveyor <NUM> functions in reverse of the entry conveyor <NUM>, and likewise with their adjacent lateral access conveyors <NUM>. Therefore, the direction of transport of the storage containers <NUM> may easily be reversed.

In another configuration, an access station <NUM> may comprise a tiltable centre access conveyor <NUM> as illustrated in <FIG>, whilst also comprising tiltable lateral access conveyors <NUM> as illustrated in <FIG> and <FIG>. Thus, storage containers <NUM> may be transported horizontally through the access station <NUM>, as in the first aspect when used with a robotic picker <NUM>, or storage containers <NUM> may be brought into the picking zone <NUM> in a tilted position as in the second aspect when used with a picking person.

<FIG> illustrates an automated storage and retrieval system <NUM> comprising an access station <NUM> for picking from storage containers <NUM> of said automated storage and retrieval system <NUM>.

The framework <NUM> of the automated storage and retrieval system <NUM> is constructed in accordance with the prior art framework <NUM> described above in connection with <FIG> and <FIG>, i.e. a number of upright members <NUM> and a number of horizontal members <NUM>, which are supported by the upright members <NUM>, and further that the framework <NUM> comprises a rail system <NUM> of parallel rails <NUM>,<NUM> in X direction and Y direction arranged across the top of storage columns <NUM> / grid columns <NUM>. The horizontal area of a grid column <NUM>, i.e. the area along the X and Y directions, may be defined by the distance between adjacent rails <NUM> and <NUM>, respectively (see <FIG>).

As illustrated in <FIG>, between the access station <NUM> and the framework <NUM> there are located a plurality of relay modules <NUM>; the relay modules are partially obscured behind the protective panels in <FIG> and <FIG>. The upper part of the relay modules <NUM> comprises a rail system <NUM> which is integrated with the rail system <NUM> of the framework <NUM> and thereby allows container handling vehicles <NUM>,<NUM> to move from the framework <NUM> to positions above the relay modules <NUM>. In <FIG> the container handling vehicles <NUM> are exemplified as those of <FIG>, however any kind of container handling vehicle <NUM>,<NUM> may be applied. Each relay module <NUM> comprises at least one conveyor on each side of a central transfer position to transport storage containers <NUM> to and from the access station <NUM>, as indicated by the arrows <NUM>. Storage containers <NUM> are thus lowered and lifted through a port column <NUM>,<NUM> by container handling vehicles <NUM> and down to the transfer position, at the transfer position the storage containers <NUM> are shifted sideways by a lateral displacement device and onto a conveyor. Simultaneously, storage containers <NUM> may be shifted from an opposing conveyor to the transfer position where they are retrieved by the container handling vehicles <NUM>. It should be noted that many variations of relay modules <NUM> can be used in accordance with the invention, with different configurations to that described above, and the relay modules <NUM> of <FIG> are merely an illustrative example.

The conveyors of the relay modules <NUM> are configured to be connected into a continuous conveyor <NUM>,<NUM>, arranged behind the protective panels <NUM> in <FIG> and <FIG>, which is further connected to the back end <NUM> of an access station <NUM>. Thus, the conveyors of the relay modules <NUM> may form a continuous conveyor <NUM>,<NUM> with the entry conveyor <NUM> and exit conveyor <NUM> of an access station <NUM>.

An order container conveyor with a plurality of order containers is illustrated in <FIG> and <FIG> passing by the access station, such that storage goods may be picked between the order containers and the storage containers. Although exemplified as order containers herein, the containers and conveyor in <FIG> and <FIG> may be storage containers and a storage conveyor leading e.g. to another automated storage and retrieval system.

In <FIG>, a picking person is illustrated picking from a tilted storage container in the picking zone of the access station. Meanwhile, the robotic picker, exemplified as a three-axis gantry robot, is shown extending over the order container conveyor and the access station, with its picking arm idle.

<FIG> illustrates a similar robotic picker as in <FIG>, however, the picking person is not present. Thus, the storage container in the picking zone of the access container is not tilted, as the robotic picker does not have the same ergonomic concerns as a human picker. Indeed, for a robotic picker with a vertical reach, an un-tilted container will be easier to pick from when reaching from above.

The present invention is particularly suited for automated storage systems where the storage containers are of varying depth. The tilting device makes it possible to ensure that the storage container is pushed all the way up, so it touches the panels around the picking zone regardless of the depth of the storage container. This makes it impossible for a person to get his or her hand inside the picking station when they are working.

Claim 1:
An access station (<NUM>) for picking storage containers (<NUM>), comprising:
- a picking zone (<NUM>),
- at least one conveyor (<NUM>,<NUM>,<NUM>,<NUM>) arranged to transport storage containers (<NUM>) from an entry position (<NUM>) through said picking zone (<NUM>) and to an exit position (<NUM>),
- at least one tilting device (<NUM>) arranged to tilt a storage container (<NUM>) at least in the picking zone (<NUM>), wherein the access station (<NUM>) further comprises: a top panel (<NUM>), a tilted top panel (<NUM>'), a front panel (<NUM>), a tilted front panel (<NUM>') and side panels (<NUM>) forming an outer housing, and covering the inner mechanism, protective paneling to shield a picking person from injury if he/she should try to reach inside the access station, the protective paneling comprises an aperture with a sliding door (<NUM>) in the picking zone (<NUM>) allowing the picking person to see one storage container at a time which minimizes the risk of picking errors and the tilting device (<NUM>) has a tilting angle range from <NUM>° to <NUM>° around a pivot axis extending along the front end (<NUM>) of the access station (<NUM>) and relative to the horizontal plane and the maximum allowed tilting angle depends on the amount and size of items / articles within the storage container.