U.S. patent application number 14/178024 was filed with the patent office on 2015-08-13 for multi-level storage system with transportation devices movable in substantially perpendicular directions and method of transferring containers in desired sequence.
The applicant listed for this patent is Sergey N. RAZUMOV. Invention is credited to Sergey N. RAZUMOV.
Application Number | 20150225187 14/178024 |
Document ID | / |
Family ID | 52469870 |
Filed Date | 2015-08-13 |
United States Patent
Application |
20150225187 |
Kind Code |
A1 |
RAZUMOV; Sergey N. |
August 13, 2015 |
MULTI-LEVEL STORAGE SYSTEM WITH TRANSPORTATION DEVICES MOVABLE IN
SUBSTANTIALLY PERPENDICULAR DIRECTIONS AND METHOD OF TRANSFERRING
CONTAINERS IN DESIRED SEQUENCE
Abstract
A storage system having multiple storage sections, each
configured for storing containers arranged in multiple rows at
various horizontal levels with respect to ground. Multiple lifting
transportation devices are configured for moving in a first
horizontal direction along pairs of first rails arranged at
predetermined horizontal levels in passages between the storage
sections so as to take containers stored in the adjacent storage
sections and place them to a selected row of the adjacent storage
sections. At least one container carriage is configured for moving
in a second horizontal direction substantially perpendicular to the
first horizontal direction so as to take the containers placed in
the selected row and move them in the second horizontal
direction.
Inventors: |
RAZUMOV; Sergey N.; (Moscow,
RU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
RAZUMOV; Sergey N. |
Moscow |
|
RU |
|
|
Family ID: |
52469870 |
Appl. No.: |
14/178024 |
Filed: |
February 11, 2014 |
Current U.S.
Class: |
414/279 ;
414/807 |
Current CPC
Class: |
B65G 1/065 20130101;
B65G 1/0492 20130101; B65G 1/0485 20130101; B65G 1/0471
20130101 |
International
Class: |
B65G 63/00 20060101
B65G063/00; B65G 63/06 20060101 B65G063/06; B65G 47/90 20060101
B65G047/90; B65G 63/02 20060101 B65G063/02 |
Claims
1. A storage system comprising: multiple storage sections, each
configured for storing containers arranged in multiple rows at
various horizontal levels with respect to ground; multiple lifting
transportation devices configured for moving in a first horizontal
direction along pairs of first rails arranged at predetermined
horizontal levels in passages between the storage sections so as to
have access to containers arranged in the storage sections, each
lifting transportation device movable along a corresponding pair of
the first rails between adjacent storage sections being configured
to include a container access mechanism movable in a vertical
direction with respect to the corresponding pair of rails so as to
take a container stored in the adjacent storage sections and place
the container to a selected row of the adjacent storage sections;
and at least one container carriage configured for moving in a
second horizontal direction substantially perpendicular to the
first horizontal direction, the container carriage being configured
for taking the container placed in the selected row and moving the
container in the second horizontal direction, wherein each lifting
transportation device and the at least one container carriage are
configured for moving in different horizontal planes with respect
to the ground so as to avoid interferences between the lifting
transportation devices and the at least one container carriage, and
the selected row of the storage sections is arranged at a
horizontal level between a horizontal plane for moving a lifting
transportation device and a horizontal plane for moving the at
least one container carriage.
2. The system of claim 1, wherein the at least one container
carriage is movable in the second horizontal direction along one or
more second rails.
3. The system of claim 2, wherein the first rails are arranged
above the selected row of the storage sections, and the second
rails are arranged below the selected row.
4. The system of claim 3, wherein the at least one container
carriage includes a board for carrying the containers, and the
container carriage is configured for raising the board so as to
take the container from the selected row.
5. The system of claim 4 including multiple container carriages
movable along respective pairs of the second rails arranged below
the selected row of the storage sections.
6. A method of transferring containers in a desired order using
multiple lifting transportation devices movable along respective
pairs of first rails in a first horizontal direction in passages
between storage sections configured for storing containers arranged
in multiple rows at various horizontal levels with respect to
ground, and using at least one container carriage movable in a
second horizontal direction substantially perpendicular to the
first horizontal direction, the method comprising the steps of:
selecting a group of containers stored in the storage sections for
transferring to a predetermined destination in a prescribed order,
controlling lifting transportation devices for moving the
containers of the selected group in a vertical direction to the
selected row of the storage sections, and controlling the at least
one container carriage for sequentially moving the containers of
the selected group from the selected row for delivery to the
predetermined destination in the prescribed order.
7. The method of claim 6, wherein the containers are transferred
using multiple container carriages movable in the second horizontal
direction.
8. The method of claim 7, further comprising: dividing the selected
group of containers into a number of subgroups, controlling lifting
transportation devices for moving the containers of the subgroups
in a vertical direction to the selected row of the storage
sections, assigning a container carriage to each of the subgroups,
and controlling each assigned container carriage to move containers
of a corresponding subgroup from the selected row in a direction of
the predetermined destination so as to deliver the containers of
the selected group in the prescribed order.
9. The method of claim 6, wherein each lifting transportation
device and the at least one container carriage are movable in
different horizontal planes with respect to the ground so as to
avoid interferences between the lifting transportation devices and
the at least one container carriage.
10. The method of claim 9, wherein the selected row of the storage
sections is arranged at a horizontal level between a horizontal
plane for moving a lifting transportation device and a horizontal
plane for moving the at least one container carriage.
11. The method of claim 10, wherein the at least one container
carriage is movable in the second horizontal direction along a pair
of second rails.
12. The method of claim 11, wherein the first rails are arranged
above the selected row of the storage sections, and the second
rails are arranged below the selected row.
13. The method of claim 8, wherein the container carriages are
movable along respective pairs of the second rails.
Description
TECHNICAL FIELD
[0001] This disclosure relates to retail logistics, and more
particularly, to a multi-level storage system in a warehouse,
fulfillment center or retail store using transportation devices
movable in substantially perpendicular horizontal directions in
different horizontal planes so as to provide point-to-point
transfers of containers.
BACKGROUND ART
[0002] Typical warehouse operations include handling and storage of
products in order to efficiently receive inventory, store it,
collect products from different containers to prepare orders, and
ship orders to customers. Handling and storage of products in a
storage system involve a number of in-storage inventory transfers
performed within the warehouse. After containers with products are
received and moved to an initial storing location, products are
often moved within the facility for storage or order selection.
Further, after an order for product shipment is received, it is
necessary to collect the required products to fulfill the order and
move orders to a shipping area.
[0003] Several transfer movements are required in a typical
warehouse. First, products are moved from the receiving area to a
remote storage location. Additional movements may be required prior
to order assembly, depending upon warehouse operating procedures.
To fulfill an order, products are usually transferred from a
storage area to a picking area. Finally, prepared orders are moved
from a picking area to a shipping dock for loading to outbound
transportation means.
[0004] In traditional storage systems, transfer movements are
carried out using a combination of lift trucks, conveyors, and
manual processes. However, such transfer operations are slow, and
involve complex logistics and substantial labor cost when a large
number of orders must be processed.
[0005] Therefore, it would be desirable to develop storage systems
capable of performing in-storage transfer operations in a quick and
efficient manner.
[0006] Also, there is a need for transferring containers within a
storage system or out of a storage system in a predetermined
sequence.
[0007] For example, during an order processing procedure when
multiple orders are fulfilled at the same time, different orders
may require collection of products from different containers. To
increase the efficiency of the order fulfillment and the throughput
of the storage system, it would be desirable to deliver containers
to a picking area in a predefined sequence so as to enable a
picking device or operator to pick products required to fulfill
processed orders sequentially. For instance, to fulfill the first
order, products stored in containers 1 and 2 may be required, to
fulfill the second order, products from containers 3 and 4 may be
needed, and to fulfill the third order, products from containers 5
and 6 should be delivered. In this case, it would be desirable to
produce a sequence of containers in which containers 3 and 4 follow
containers 1 and 2, and containers 5 and 6 follow containers 3 and
4.
[0008] Also, an order may include multiple products that should be
packed in a specific sequence. For example, heavy products need to
be placed at the bottom of the container, while lightweight
products may be placed after the heavy products. In this case, to
efficiently fulfill the order, it would be desirable to deliver
containers with the heavy products before containers with the
lightweight products.
[0009] Further, trucks used for shipping orders from a warehouse or
fulfillment center should be loaded in accordance with order
destinations so as to make it possible to unload containers
delivered to closer destinations without unloading the remaining
containers from the truck. In this case, it would be desirable to
transfer containers to truck loading ports in an order determined
by containers' destinations.
SUMMARY OF THE DISCLOSURE
[0010] In accordance with one aspect of the disclosure, the present
disclosure offers a storage system having multiple storage
sections, each configured for storing containers arranged in
multiple rows at various horizontal levels with respect to ground.
Multiple lifting transportation devices are configured for moving
in a first horizontal direction along pairs of first rails arranged
at predetermined horizontal levels in passages between the storage
sections so as to have access to containers arranged in the storage
sections.
[0011] Each lifting transportation device movable along a
corresponding pair of the first rails between adjacent storage
sections is configured to include a container access mechanism
movable in a vertical direction with respect to the corresponding
pair of rails so as to take a container stored in the adjacent
storage sections and place the container to a selected row of the
adjacent storage sections.
[0012] At least one container carriage is configured for moving in
a second horizontal direction substantially perpendicular to the
first horizontal direction. The container carriage is further
configured for taking the container placed to the selected row and
moving the container in the second horizontal direction.
[0013] Each lifting transportation device and the at least one
container carriage are configured for moving in different
horizontal planes with respect to the ground so as to avoid
interferences between the lifting transportation devices and the at
least one container carriage.
[0014] The selected row of the storage sections is arranged at a
horizontal level between a horizontal plane for moving a lifting
transportation device and a horizontal plane for moving the at
least one container carriage.
[0015] In an exemplary embodiment, the container carriage may be
movable in the second horizontal direction along a pair of second
rails.
[0016] The first rails may be arranged above the selected row of
the storage sections, and the second rails may be arranged below
the selected row.
[0017] The container carriage may include a board for carrying the
containers, and may be configured for raising the board so as to
take the container from the selected row.
[0018] Multiple container carriages may be provided in the storage
system for carrying containers along respective pairs of the second
rails arranged below the selected row of the storage sections.
[0019] In accordance with another aspect of the disclosure, a
method of transferring containers in a desired order is offered.
The method uses multiple lifting transportation devices movable
along respective pairs of first rails in a first horizontal
direction in passages between storage sections configured for
storing containers arranged in multiple rows at various horizontal
levels with respect to ground. The method also uses at least one
container carriage movable in a second horizontal direction
substantially perpendicular to the first horizontal direction.
[0020] The following steps are performed to provide a desired
sequence of containers:
[0021] selecting a group of containers stored in the storage
sections for transferring to a predetermined destination in a
prescribed order,
[0022] controlling lifting transportation devices for moving the
containers of the selected group in a vertical direction to the
selected row of the storage sections, and
[0023] controlling the at least one container carriage for
sequentially moving the containers of the selected group from the
selected row for delivery to the predetermined destination in the
prescribed order.
[0024] In accordance with a further aspect, a desired sequence of
containers may be provided using multiple container carriages
movable in the second horizontal direction.
[0025] In this case, the selected group of containers may be
divided into a number of subgroups. Lifting transportation devices
may be controlled for moving the containers of the subgroups in a
vertical direction to the selected row of the storage sections.
[0026] A container carriage may be assigned to each of the
subgroups. Each assigned container carriage may be controlled to
move containers of a corresponding subgroup from the selected row
in a direction of the predetermined destination so as to deliver
the containers of the selected group in the prescribed order.
[0027] Each lifting transportation device and the at least one
container carriage may move in different horizontal planes with
respect to the ground so as to avoid interferences between the
lifting transportation devices and the at least one container
carriage.
[0028] The selected row of the storage sections may be arranged at
a horizontal level between a horizontal plane for moving a lifting
transportation device and a horizontal plane for moving the at
least one container carriage.
[0029] The container carriage may move in the second horizontal
direction along a pair of second rails.
[0030] The first rails may be arranged above the selected row of
the storage sections, and the second rails may be arranged below
the selected row.
[0031] If the method is implemented using multiple container
carriages, each of them may move along respective pairs of the
second rails.
[0032] Additional advantages and aspects of the disclosure will
become readily apparent to those skilled in the art from the
following detailed description, wherein embodiments of the present
disclosure are shown and described, simply by way of illustration
of the best mode contemplated for practicing the present
disclosure. As will be described, the disclosure is capable of
other and different embodiments, and its several details are
susceptible of modification in various obvious respects, all
without departing from the spirit of the disclosure. Accordingly,
the drawings and description are to be regarded as illustrative in
nature, and not as limitative.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The following detailed description of the embodiments of the
present disclosure can best be understood when read in conjunction
with the following drawings, in which the features are not
necessarily drawn to scale but rather are drawn as to best
illustrate the pertinent features, wherein:
[0034] FIG. 1 shows an exemplary storage system of the present
disclosure.
[0035] FIGS. 2-5 illustrate exemplary configurations of a lifting
transportation device that may be used in the storage system of the
present disclosure.
[0036] FIGS. 6-9 illustrate operations of exemplary container
carriages that can be used in the storage system.
[0037] FIGS. 10-17 illustrate exemplary operations performed by the
container carriage to move a container from one storage rack to
another storage rack.
[0038] FIGS. 18-33 show an example of a sequencing procedure of the
present disclosure performed using a single container carriage.
[0039] FIGS. 34-39 illustrate an example of a sequencing procedure
of the present disclosure performed using multiple container
carriages.
DETAILED DISCLOSURE OF THE EMBODIMENTS
[0040] The present disclosure will be made using exemplary storage
environment discussed below. It will become apparent, however, that
the concept of the disclosure is applicable to any storage system
using transportation devices movable in substantially perpendicular
horizontal directions in different horizontal planes.
[0041] FIG. 1 illustrates an exemplary embodiment of a storage
system 10 in accordance with the present disclosure. The storage
system 10 may be arranged in a warehouse, fulfillment center or
retail facility for storing products. The storage system 10 may
include not only a storage area, but also a picking area in which
products are collected to fulfill customers' orders.
[0042] The storage system 10 may include storage racks 12, 14, 16
and 18, each of which is configured for storing containers arranged
in a vertical direction in multiple rows at various horizontal
levels with respect to the ground. The containers may be any
objects capable of holding goods stored in the storage area, such
as cartons, boxes, crates, or pallets.
[0043] As shown in FIG. 1, each row of the storage rack may contain
multiple containers arranged in two mutually perpendicular
horizontal directions. The storage racks 12, 14, 16 and 18 may be
arranged so as to provide passages between adjacent racks. Lifting
transportation devices may be provided in the passages to handle
containers stored in adjacent section racks from both sides of the
corresponding passage. For example, lifting transportation devices
A1, A2 and A3 may be arranged in the passage between the storage
racks 12 and 14 to handle containers stored in these racks, lifting
transportation devices B1, B2 and B3 may be arranged in the passage
between the storage racks 14 and 16, and lifting transportation
devices C1, C2 and C3 may be arranged in the passage between the
storage racks 16 and 18.
[0044] Although FIG. 1 shows an example in which several lifting
transportation devices are provided in each passage, the concept of
the present disclosure is applicable to a storage system using a
single lifting transportation device between the adjacent storage
sections, or using one or more lifting transportation devices to
serve a single storage section.
[0045] The lifting transportation devices are configured for moving
in a horizontal direction along corresponding pairs of rails 20
arranged at multiple horizontal levels in each passage so as to
have access to containers arranged in storage racks on both sides
of the passage. In particular, the rails 20 provided for the
transportation devices A1, B1 and C1 are arranged below the rails
20 provided for the transportation devices A2, B2 and C2, and the
rails 20 provided for the transportation devices A3, B3 and C3 are
arranged above the rails 20 for the transportation devices A2, B2
and C2.
[0046] As discussed in more detail below, each lifting
transportation device includes a frame movable along a selected
pair of rails and a movable platform configured to move up and down
with respect to the frame so as to handle containers provided above
and below the corresponding pair of rails 20. In particular, a
lifting transportation device may load a container from one
selected row of the adjacent storage racks, and may unload that
container to another selected row of the storage racks. The
container may be unloaded to the same storage rack from which the
container is taken. Alternatively, the container may be loaded from
one storage section served by the transportation device and
unloaded to the other storage rack served by the transportation
device.
[0047] Further, the system 10 includes container carriages 22
movable in a horizontal direction substantially perpendicular to
the horizontal direction in which the lifting transportation
devices move. For example, the container carriages 22 may be
configured for moving along corresponding pairs of rails 24 that
may be arranged in the same horizontal plane in a horizontal
direction substantially perpendicular to the direction of the rails
20. The pairs of rails 24 may be arranged below a selected row of
the storage racks 12, 14, 16 and 18 so as to enable the container
carriage 22 to access containers held in the selected row. Also,
the container carriage 22 may be configured to move along a single
rail 24, or to move without rails at all. As discussed in more
detail below, each container carriage 22 may have a board for
carrying containers. The board may be raised with respect to the
rails 24 so as to take a container from the selected row or to
place the container to the selected row.
[0048] For example, the rails 24 may be arranged on the floor of
the storage facility. Multiple pairs of rails 24 may be arranged in
parallel so as to provide access of the respective container
carriages 22 to containers held in the selected row above the
respective pairs of rails 24.
[0049] To avoid interferences between the container carriages 22
and the lifting transportation devices A1-A3, B1-B3 and C1-C3, the
pairs of rails 24 and the pairs of rails 20 are arranged on
different horizontal planes with respect to the ground so as to
provide movement of each container carriage 22 and each lifting
transportation device in different horizontal planes with respect
to the ground.
[0050] Each of the lifting transportation devices A1-A3, B1-B3 and
C1-C3 is configured to take a container stored in any row of the
adjacent storage racks and place the container to a selected row
accessible by the container carriages 22. The selected row is
arranged at a horizontal level between a horizontal plane for
moving a lifting transportation device and a horizontal plane for
moving a container carriage. For example, FIG. 1 shows that the
lowest row of the storage racks 12, 14, 16 and 18 is accessible by
the container carriages 22 movable along the respective pairs of
rails 24 below the respective containers of the lowest row in the
storage racks 12, 14, 16 and 18.
[0051] The storage system 10 provides a point-to-point transfer of
a container using a lifting transportation device to transfer the
container from a point in which the container is stored in the
storage section to a transit storage point in a selected row, and
then using a container carriage to transfer the container from the
transit point in the selected row to a desired destination point.
For example, containers may be transferred to a picking area in
which a picking device or operator collects required products from
the containers to fulfill an order.
[0052] The point-to-point transfer of the present disclosure makes
it possible to transfer containers without using expensive
container transferring systems such as a conveyor system. In
addition, the point-to-point container transfer of the present
disclosure substantially reduces the time required to transfer
containers between various points in the storage system.
[0053] FIG. 1 shows that the horizontal level corresponding to the
storage row accessible by the container carriages 22 is below the
horizontal plane in which rails 20 for moving the lifting
transportation devices A1, B1 and C1 are arranged, but above the
horizontal plane in which rails 24 for moving the container
carriages 22 are provided. However, the concept of the present
disclosure is also applicable to the storage arrangement in which
the container carriages 22 are provided above the lifting
transportation devices. For example, the container carriages 22 may
be configured as cable cars movable in a horizontal direction above
the storage racks to take the containers from a selected row of the
storage racks.
[0054] Although FIG. 1 shows multiple container carriages 22 for
transferring containers from the respective storage locations in
the selected row, the system 10 may be implemented using a single
container carriage 22 configured for accessing all required storage
locations in which containers delivered by the lifting
transportation devices are held.
[0055] FIGS. 2-5 schematically illustrate an exemplary embodiment
of the lifting transportation device that may be used in the
storage system 10. As shown in FIG. 2, a lifting transportation
device 100 may include a frame 102 with four wheels 104 fixed to
the frame 102 which may be formed as a braced structure for
supporting elements required to operate the lifting transportation
device 100. Each wheel 104 may be attached to the frame 102 so as
to rotate in a vertical plane about an axis extending from the
center of the wheel 104 in order to move the transportation device
100 along the rails 20.
[0056] The frame 102 may hold a movable platform 106 that can be
used for carrying containers. For example, the platform 106 may be
a rectangular metal plate configured to accommodate containers.
Side walls 108 may be provided on the frame 102 to support loading
and carrying containers.
[0057] The platform 106 may move in a vertical direction up and
down with respect to the frame 102 so as to access containers
arranged in rows above and below the level at which the rails 20
are arranged. A platform lifting mechanism 110 may be arranged at
the side walls 108 to move the platform 106 in a vertical
direction. The platform lifting mechanism 110 may be implemented
using any well-known mechanisms for moving a plate up and down. For
example, a telescopic mechanism can be utilized.
[0058] One or more handling elements 112 may be mounted on the
platform 106 and configured for operating with containers. The
handling elements 112 may take one or more containers from one row
of the storage rack, place the container onto the transportation
unit 100 for carrying to another row, and remove the container from
the transportation device 100 for placing it at a selected row. The
handling elements 112 may be extended in a horizontal direction
from one or both sides of the transportation device 100 so as to
handle containers arranged at one storage rack or both storage
racks served by the transportation device 100. For example, the
handling elements 112 may be implemented as a metal plate, spade,
fork or pulling device.
[0059] FIG. 3 illustrates the lifting transportation device 100
with the handling elements 112 extended from both sides of the
lifting transportation device 100. FIG. 4 illustrates the lifting
transportation device 100 with the movable platform 106 moved down
with respect to the frame 102 so as to handle containers arranged
in rows below the level of the corresponding rails 20. FIG. 5
illustrates the lifting transportation device 100 with the movable
platform 106 raised with respect to the frame 102 so as to handle
containers arranged in rows above the level of the corresponding
rails 20.
[0060] The operations of each lifting transportation device 100 may
be controlled by a controller that may include a data processor
responsive to external commands for processing the commands and
producing various control signals. The controller may communicate
with various elements of the lifting transportation unit 100 to
supply control signals to the elements of the transportation unit
100 and receive responses.
[0061] FIGS. 2-5 show a lifting transportation device having the
wheels 104 attached at the lower portion of the frame 102. However,
the wheels 104 may be attached at the upper portion of the frame
102 or at the middle portion of the frame 102. An exemplary
transportation device that can be used as a lifting transportation
device in the storage system 10 is described in more detail in my
copending U.S. patent application Ser. No. 14/049,552 filed on Oct.
9, 2013 and entitled "AUTOMATIC ORDER PICKING SYSTEM AND METHOD IN
RETAIL FACILITY," and in my copending U.S. patent application Ser.
No. 14/155,976 filed on Jan. 15, 2014 and entitled "TRANSFERRING
CONTAINERS IN STORAGE SYSTEM," both incorporated herewith by
reference.
[0062] Due to ability of transportation devices to move the
platform 106 up and down in a horizontal direction, adjacent
transportation devices arranged at the same passage between storage
racks can simultaneously operate with containers arranged at the
same row. For example, the transportation device A1 may load one or
more container from a row in the storage section 12. At the same
time, the transportation device A2 may unload one or more
containers to the same row. To avoid interference between the
transportation devices A1 and A2 when both of them cross the same
point, the platform 106 of the transportation device A1 may be
moved down and/or the platform 106 of the transportation device A2
may be moved up. As a result, the storage system 10 can provide a
high-speed transfer of containers from any slot of the storage
racks to another slot in a selected row of the storage racks
accessible to the container carriage 22.
[0063] FIGS. 6-9 illustrate operations of exemplary container
carriages 22 that can be used in the system 10 of the present
disclosure. The container carriage 22 may include a frame 220 with
four wheels 240 fixed to the frame 220 which may be formed as a
braced structure for supporting elements required to operate the
container carriage. 22. Each wheel 240 may be attached to the frame
220 so as to rotate in a vertical plane about an axis extending
from the center of the wheel 240 in order to move the container
carriage 22 along the rails 24.
[0064] The frame 220 may hold a board 260 that can be used for
carrying containers. For example, the board 260 may be a
rectangular metal plate configured to accommodate containers. A
pantograph mechanism 280 may be provided on the frame 220 to raise
the board 260 with respect to the frame 220 in order to place
containers on the board 260, or to move the board 260 down to a
folded position so as to enable the container carriage 22 to move
under the row of containers.
[0065] As shown in FIG. 6, the container carriage 22 with the board
260 in a folded position may be moved along a respective pair of
rails 22 to a location under storage cells at which one or more
selected containers are held. Thereafter, as shown in FIG. 7, using
the pantograph mechanism 280, the board 260 may be raised slightly
above the lowest vertical level of the respective storage row to
place the selected containers on the board 260. The size of the
board 260 in a direction perpendicular to the rails 22 may be
selected so as to be less than the distance between holding
elements that hold containers in the storage racks.
[0066] As shown in FIG. 8, when the containers are placed on the
board 260, the container carriage 22 may be moved to a location in
the passage between the storage racks. The board 260 carrying the
containers is moved down to a folded position in which the
container carriage 22 can pass under the storage rows (FIG. 9). The
operations of each container carriage 22 may be controlled by a
controller that may include a data processor responsive to external
commands for processing the commands and producing various control
signals.
[0067] FIGS. 10-17 illustrate exemplary operations performed by the
container carriage 22 to move a container from one storage rack to
another storage rack. For example, a lifting transportation device
(not shown) may place a container 300 to a transit point in a
selected row of the storage rack 16. The container carriage 22 may
move the container 300 from the transit point to a desired
destination point in a selected row of the storage rack 12.
[0068] As shown in FIG. 10, the container carriage 22 with the
folded board 260 is moved in a position below the container 300.
The board 260 is raised to place the container 300 on the board
(FIG. 11). Then, the container carriage 22 with the container 300
is moved to a passage between the storage racks 16 and 14 (FIG.
12), where the board 260 is moved down (FIG. 13).
[0069] As shown in FIG. 14, the container carriage 22 with the
folded board 260 and container 300 is moved along the rails 24
under the lowest row of the storage rack 14 to a selected location
in the passage between the storage racks 12 and 14. Thereafter, the
board 260 is raised slightly above the lowest vertical level of the
row at which the container 300 should be placed (FIG. 15).
[0070] Then, as shown in FIG. 16, the container carriage 22 with
the raised board 260 is moved along the rails 24 in the direction
of the storage rack 12 to place the container 300 on the board 260
to a position corresponding to the storage location at which the
container 300 should be placed. Thereafter, the board 260 is
lowered down leaving the container 300 held by holding elements of
the storage rack 12 (FIG. 17).
[0071] Hence, the storage system 10 of the present disclosure may
provide a point-to-point transfer of a selected container 300 from
a starting point at which the container 300 is stored to a transit
point at a selected row of a selected storage rack, and from the
transit point to a destination point at the selected row of a
storage rack which is not adjacent to the storage rack from which
the container 300 is delivered.
[0072] The transfer procedures may be controlled by a control unit
including a data processor responsive to external commands for
processing the commands and producing various control signals.
[0073] FIGS. 18-33 illustrate an exemplary sequencing procedure of
the present disclosure that may be implemented in the storage
system 10 to deliver containers to a selected destination point in
a desired sequence. For example, a desired sequence of containers
C1 to C6 stored in various storage racks may be delivered to a
picking area where a picking device or operator fulfills an order
by collecting different ordered items from various containers
delivered to the picking area. The picking area may be arranged
adjacent to a selected storage row in the storage rack 18. The
sequencing procedure may be controlled by a central processing unit
that executes a software program defining operations of the
sequencing procedure.
[0074] FIGS. 18-33 show an example of a sequencing procedure
performed using a single container carriage 22. As discussed later,
the sequencing procedure may be also implemented using multiple
container carriages 22. Also, to maintain the clarity of the
drawings, the lifting transportation devices used for implementing
the sequencing procedure are not shown.
[0075] Referring to FIG. 18, a lifting transportation device (not
shown) movable along the rails 20 between the storage racks 14 and
16 may transfer container C1 stored in the storage rack 16 to
storage location C1a in the selected storage row above rails 24
used for a container carriage 22 selected for implementing the
sequencing procedure. At the same time, the lifting transportation
device that operates along the rails 20 between the storage racks
12 and 14 may transfer container C2 storage in the storage rack 14
to storage location C2a in the selected storage row above the rails
24 for the selected container carriage 22. Simultaneously with
operations of the lifting transportation devices, the selected
container carriage 22 with a folded board may be moved along the
rails 24 to a position below the storage location C1a.
[0076] As shown in FIG. 19, the board of the container carriage 22
is raised to place the container C1 on the board. At the same time,
the respective lifting transportation devices may move containers
C3 and C4 down to storage locations C3a and C5a in the selected
storage row.
[0077] Referring to FIG. 20, the container carriage 22 is
controlled to move down its board carrying container C1, and to go
along the rails 24 toward a position below the storage location C2a
where the container C2 is held. When the container carriage 22
reaches the position below the location C2a, its board is raised to
place container C2 on the board, together with container C1 (FIG.
21).
[0078] Thereafter, as shown in FIG. 22, the container carriage 22
with the containers C1 and C2 on the folded board is moved under
the rows of the storage racks 14 and 16 toward the selected
destination point. When the container carriage 22 reaches the
passage between the racks 16 and 18, its board is raised to place
container C1 followed by container C2 to the selected row of the
storage rack 18 (FIG. 23). Thereafter, container C1 followed by
container C2 may be transferred to the picking area adjacent to the
selected row of the storage rack 18.
[0079] As shown in FIG. 24, after removing containers C1 and C2,
the container carriage 22 is moved toward a position below the
storage location C4a where container C4 is held. At the same time,
container C6 may be moved by the respected lifting transportation
device to storage location C6a in the selected row of the storage
rack 12.
[0080] As illustrated in FIG. 25, after the container carriage 22
reaches the position below container C4, its board is raised to
place container C4 on the board. Then, the container carriage 22
may be transferred to the passage between racks 14 and 16 to lower
its board that carries container C4 (FIG. 26).
[0081] Then, the container carriage 22 with container C4 may be
moved below the rack 14 to a position below the storage location
where container C3 is held, so as to position container C4 in the
passage between the racks 12 and 14 (FIG. 27). Thereafter, the
board is raised to place container C3 in front of the container
C4.
[0082] As shown in FIG. 28, the container carriage 22 is moved to
position both containers C3 and C4 in the passage between the racks
12 and 14. Then, the board is lowered to carry containers C3 and C4
under the racks 14 and 16 toward the rack 18.
[0083] As shown in FIG. 29, when the carriage 22 reaches a position
in which containers C3 and C4 are located in the passage between
the racks 16 and 18, the board is raised to place container C3
followed by container C4 to the selected row in the storage rack
18. Thereafter, containers C3 and C4 may follow containers C1 and
C2 into the picking area.
[0084] Referring to FIG. 30, after removing containers C3 and C4,
the carriage 22 with the folded board is moved toward the storage
location in which container C5 is held. After the board is raised
to place container C5 on the board, carriage is moved to the
passage between the racks 14 and 16, where the board is lowered to
allow the carriage to pass under the rows of the rack 14 to the
passage between the racks 12 and 14 (FIG. 31).
[0085] As shown in FIG. 32, when the carriage 22 carrying container
C5 reaches a position below the storage location in which container
C6 is held, the board is raised so as to place container C6 next to
container C5. Then, the board is lowered to deliver containers C5
and C6 under the rows of the racks 14 and 16 to the passage between
the racks 16 and 18.
[0086] Thereafter, as shown in FIG. 33, the board is raised again
to place container C5 followed by container C6 to the selected row
in the rack 18. Then, containers C5 and C6 may follow containers
C1, C2, C3 and C4 into the picking area.
[0087] FIGS. 34-39 illustrate another example of the sequencing
procedure of the present disclosure that may be implemented in the
storage system 10 to deliver containers to a selected destination
point in a desired sequence. In this example, multiple container
carriages 22 may be used for delivery a desired sequence of
containers C1, C2, C3, C4, C5 and C6 respectively stored in storage
locations C1a, C2a, C3a, C4a, C5a and C6a (FIG. 34) in various rows
of storage racks 12, 14 and 16 to storage locations C1c, C2c, C3c,
C4c, C5c and C6c in a selected row of a storage rack 18 adjacent to
a picking area. The containers C1 to C6 may be divided into a
number of subgroups corresponding to the number of container
carriages 22 used for the sequencing procedure. For example, a
container carriage 22-1 may be assigned for delivery the containers
C1 and C2, a container carriage 22-2 may be assigned for
transferring the containers C3 and C4, and a container carriage
22-3 may be assigned for transferring the containers C5 and C6.
[0088] Referring to FIG. 35, the containers C1, C2, C3, C4, C5 and
C6 are transferred by the respective lifting transportation devices
(not shown) from the storage locations C1a, C2a, C3a, C4a, C5a and
C6a to transit storage locations C1b, C2b, C3b, C4b, C5b and C6b in
the selected row of the storage racks 12, 14 and 16. The storage
locations C1b and C2b are provided above the rails 24 used for
moving the container carriage 22-1, the storage locations C3b and
C4b are arranged above the rails 24 used for the container carriage
22-2, and the storage locations C5b and C6b are provided above the
rails 24 used for moving the container carriage 22-3.
[0089] As shown in FIG. 36, the container carriage 22-1 may be
moved to a position below the container C1 to take this container
on its board, the container carriage 22-2 may be moved to a
position below the container C3 to take this container, and the
container carriage 22-3 may be moved to a position below the
container C5 to take this container.
[0090] Referring to FIG. 37, the carriage 22-1 with the container
C1 is moved to the position below the container C2 to place this
container next to the container C1, the carriage 22-2 with the
container C3 is moved to the position below the container C4 to
place this container next to the container C3, and the carriage
22-3 with the container C5 is moved to the position below the
container C6 to place this container next to the container C5.
[0091] As shown in FIG. 38, the carriage 22-1 with the containers
C1 and C2, the carriage 22-2 with the containers C3 and C4, and the
carriage 22-3 with the containers C5 and C6 are moved in the
direction of the storage rack 18. Referring to FIG. 39, the
containers C1, C2, C3, C4 and C5, C6 are unloaded from the
respected carriages 22-1, 22-2 and 22-3 to the storage locations in
the selected row of the storage rack 18. From these locations, they
may be moved to the adjacent picking area.
[0092] The foregoing description illustrates and describes aspects
of the present invention. Additionally, the disclosure shows and
describes only preferred embodiments, but as aforementioned, it is
to be understood that the invention is capable of use in various
other combinations, modifications, and environments and is capable
of changes or modifications within the scope of the inventive
concept as expressed herein, commensurate with the above teachings,
and/or the skill or knowledge of the relevant art.
[0093] The embodiments described hereinabove are further intended
to explain best modes known of practicing the invention and to
enable others skilled in the art to utilize the invention in such,
or other, embodiments and with the various modifications required
by the particular applications or uses of the invention.
Accordingly, the description is not intended to limit the invention
to the form disclosed herein.
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