US-20260125214-A1 - VERTICAL CAROUSEL

US20260125214A1US 20260125214 A1US20260125214 A1US 20260125214A1US-20260125214-A1

Abstract

A storage and retrieval system is provided. The system includes: a) a track system, the track system comprising a plurality of grid members or tracks arranged in a grid pattern comprising a plurality of grid cells or spaces; b) at least one vertical carousel comprising a drive mechanism for circulating a plurality of containers around a vertical endless loop from a lowermost position to an uppermost position adjacent to the track system; c) a control system operatively coupled to the drive mechanism, the control system being configured to index the plurality of containers around the endless vertical loop in sequential steps, each of the sequential steps corresponding to at least one of the plurality of storage containers being aligned with a grid space or grid cell of the track system such that a storage container can be retrieved and/or lowered through the grid cell or grid space.

Inventors

Leslie Wynn
Oliver Frederick KIRKBY
Keith Derek HABBEN

Assignees

OCADO INNOVATION LIMITED

Dates

Publication Date: 20260507
Application Date: 20251106
Priority Date: 20230510

Claims (20)

1 . A storage and retrieval system comprising: a) a track system, the track system comprising a plurality of grid members or tracks arranged in a grid pattern comprising a plurality of grid cells or spaces; b) at least one vertical carousel comprising a drive mechanism for circulating a plurality of storage containers around a vertical endless loop from a lowermost position to an uppermost position adjacent to the track system; c) a control system operatively coupled to the drive mechanism, the control system being configured to index the plurality of containers around the endless vertical loop in sequential steps, each of the sequential steps corresponding to at least one of the plurality of storage containers being aligned with a grid space or grid cell of the track system such that a storage container can be retrieved and/or lowered through the grid cell or grid space.
2 . A system according to claim 1 , wherein the at least one vertical carousel has a width that occupies only two grid cells.
3 . A system according to claim 1 , wherein the at least one vertical carousel further comprises a series of carriers for accommodating and conveying the plurality of storage containers.
4 . The system according to claim 3 , wherein a height of the at least one vertical carousel is greater than its width such that the series of carriers are arranged vertically.
5 . A system according to claim 3 , wherein the carriers comprise shelving.
6 . A system according to claim 3 , wherein each carrier accommodates a row of storage containers.
7 . A system according to claim 1 , wherein the lowermost position is arranged to allow retrieval of storage containers at ground level.
8 . A system according to claim 1 , wherein the at least one vertical carousel comprises a plurality of vertical carousels, said plurality of vertical carousels being disposed laterally to each other to form a row of vertical carousels.
9 . A system according to claim 8 , wherein each of the plurality of vertical carousels being configured to operate independently or in synchronisation.
10 . A system according to claim 1 , wherein the system further comprises a load handling device, wherein the load handling device is moveable and operable on the track system, the load handling device comprising a container lifting mechanism for retrieving and/or lowering a storage container through a grid cell or grid space, the container lifting mechanism comprising a grabber device configured to releasably grip a container, and a drive mechanism configured to raise and lower the grabber device.
11 . The system according to claim 1 , further comprising one or more access positions between the uppermost position and the lowermost position of the endless vertical loop for accessing the content of one or more storage containers from the side of the at least one vertical carousel.
12 . The system according to claim 11 , further comprising at least one transfer system disposed laterally to the at least one vertical carousel, said transfer system comprising a transfer mechanism configured to transfer a storage container between a stowed position at the access position of the vertical carousel and a deployed position outwardly relative to the at least one vertical carousel such that the contents of the storage container can be accessed therein.
13 . The system according to claim 12 , wherein said at least one transfer system further comprises a transfer conveyance system for transporting a container across at least one vertical carousel, said transfer conveyance system is disposed laterally to the at least one vertical carousel.
14 . The system according to claim 12 , wherein the transfer mechanism comprises at least one grabber device moveable in a direction substantially perpendicular to an axis of rotation of the vertical endless loop to engage with a storage container at the access position.
15 . The system according to claim 12 , wherein the transfer mechanism comprises at least one shuttle having a support deck for supporting a storage container, said shuttle being moveable along one or more tracks across the at least one carousel.
16 . The system according to claim 12 , wherein the at least one transfer system comprises a first transfer system and a second transfer system, said first transfer system being configured to transfer at least one storage container from the at least one vertical carousel to the deployed position and said second transfer system being configured to transfer at least one storage container to the stowed position in the at least one vertical carousel.
17 . The system according to claim 12 , further comprises a picking mechanism comprising a picking arm comprising an end effector configured to pick one or more items from the storage container in the deployed position and transfer the one or more picked items to one or more delivery containers.
18 . The system of claim 17 , wherein the picking mechanism is mounted to a gantry, said gantry being configured to move the picking mechanism in a lateral direction between the retrieval container mechanism and the transfer conveyance system.
19 . A method of moving a storage container around a storage and retrieval system, the storage and retrieval system comprising: a) a track system comprising a plurality of grid members to form a grid pattern comprising a plurality of grid cells or spaces; b) at least one vertical carousel comprising a drive mechanism for circulating a plurality of containers around a vertical endless loop from a lowermost position to an uppermost position adjacent to the track system; c) a control system operatively coupled to the drive mechanism, the control system being configured to index the plurality of containers around the endless vertical loop in sequential steps, each of the sequential steps corresponding to at least one of the plurality of storage containers being aligned with a grid space or grid cell of the track system such that a storage container can be retrieved and/or lowered through the grid cell or grid space; the method comprising the steps of: i) circulating the vertical carousel such that a desired storage container on the vertical carousel is at one or more access positions between the uppermost position and lowermost position of the endless vertical loop for accessing the content of one or more storage containers from the side of the at least one vertical carousel; ii) removing the desired storage container from the vertical carousel by moving the desired storage container outwardly relative to the vertical carousel to define a deployed position.
20 . The method of claim 19 , wherein the at least one vertical carousel comprises a plurality of vertical carousels, said plurality of vertical carousels being disposed laterally to each other to form a row of vertical carousels, said control system operatively coupled to the drive mechanism of each of the plurality of vertical carousels to drive each of the plurality of vertical carousels independently or in synchronisation.

Description

TECHNICAL FIELD The present invention relates to the field of storage and retrieval systems comprising robotic load handling devices operative on tracks located on a grid framework structure for handling storage containers stored in the grid framework structure. BACKGROUND Some commercial and industrial activities require systems that enable the storage and retrieval of a large number of different products. One known type of system for the storage and retrieval of items in multiple product lines involves arranging storage containers (also known as bins or totes) in stacks on top of one another, the stacks being arranged in rows. The storage containers are removed from the stacks and accessed from above by load handling devices, removing the need for aisles between the rows and thereby allowing a large number of containers to be stored in a given space. As shown in FIGS. 1 and 2, the storage containers 10, also known as bins or totes, are stacked on top of one another to form stacks 12. The stacks 12 are arranged in a grid framework structure 14 in a warehousing or manufacturing environment. The grid framework is made up of a plurality of storage columns or grid columns 11. Each grid in the grid framework structure has at least one storage column 11 for storage of a stack of containers. FIG. 1 is a schematic perspective view of the grid framework structure 14, and FIG. 2 is a top-down view showing a single stack 12 of containers 10 arranged within the framework structure 14. Each container or bin 10 typically holds a plurality of product items (not shown), and the product items within a container 10 may be identical, or may be of different product types depending on the application. Each container 10 may be used to store grocery items (i.e. food items), for example. Furthermore, the bins 10 may be physically subdivided to accommodate a plurality of different inventory items. The grid framework structure 14 comprises a plurality of upright members or upright columns 16 that support horizontal members 18, 20. A first set of parallel horizontal grid members 18 is arranged perpendicularly to a second set of parallel horizontal grid members 20 to form a grid structure lying in a substantially horizontal plane and supported by the upright members 16. The members 16, 18, 20 are typically manufactured from metal and typically welded or bolted together or a combination of both. The storage containers 10 are stacked between the upright members 16 of the grid framework structure 14, so that the grid framework structure 14 guards against horizontal movement of the stacks 12 of the storage containers 10, and guides vertical movement of the storage containers 10. The top level of the grid framework structure 14 includes a track system 15 comprising a plurality of grid members, rails or tracks 22 arranged in a grid pattern across the top of the stacks 12. Referring additionally to FIG. 3, the rails 22 support a plurality of load handling devices or robotic load handling devices 30. A first set 22a of parallel rails 22 guide movement of the robotic load handling devices 30 in a first direction (for example, an X-direction) across the top of the grid framework structure 14, and a second set 22b of parallel rails 22, arranged perpendicular to the first set 22a, guide movement of the load handling devices 30 in a second direction (for example, a Y-direction), perpendicular to the first direction. In this way, the rails 22 allow movement of the robotic load handling devices 30 laterally in two dimensions in the horizontal X-Y plane, so that a load handling device 30 can be moved into position above any of the stacks 12. The track system 15 can be integrated into the grid structure in the sense that the first and second sets of tracks are respectively integrated into the first and second set of grid members. Alternatively, the track system 15 can be separate to the grid structure in the sense that the first and second sets of tracks are respectively mounted to the first and second sets of grid members. The system described with reference to FIGS. 1 to 3 is generally described as a “cubic” storage system and has many advantages and is suitable for a wide range of storage and retrieval operations. In particular, it allows very dense storage of product, and it provides a very economical way of storing a huge range of different items in the containers 10, while allowing reasonably economical access to all of the containers when required for picking. Each load handling device 30 comprises a vehicle body 32 which is arranged to travel in the X and Y directions on the tracks or rails 22 of the grid frame structure 14, above the stacks 12 (see FIG. 4). FIGS. 4 and 5A-5B shows a load handling device 30 described in PCT Patent Publication No. WO2015/019055 (Ocado Innovation Limited) and International patent application WO 2015/140216 (Ocado Innovation Limited) comprising a vehicle body 32 equipped with a lifting mechanism 33 comprising a