EP0203075A1 - Modular storage and retrieval system for automobiles and the like - Google Patents

Abstract

A storage and retrieval system, particularly of automobiles, is a substantially vertical structure having a central shaft and elevator shaft for raising automobiles to a designated storage floor. Each tier includes a right stall and a left stall into which an automatic controller transfers a pallet (60) containing the automobile and then retrieves them. Each plurality of floors is a modular structure comprising four column sections (11, 12, 13, 14) formed from square tubes arranged at the four corners, and horizontal beams (25, 26, 27, 28) connecting the columns and supported by suitable crosspieces. Tier modules can be stacked on top of each other at vertical columns by a single corner connector (41, 42) placed at each corner of the modular frame, and by a thrust bearing plate (50) that covers the upper end of each lower column module, which allows each module to be laid flat on the end of the lower columns, the load being evenly distributed. The columns are held together by bolts that pass through the angles of the corner connectors and the vertical columns, holding the modules on top of each other. The floor modules are stacked concentrically around the elevator shaft, which serves all of the floor modules.

Description

MODULAR STORAGE AND RETRIEVAL SYSTEM FOR AUTOMOBILES AND THE LIKE BACKG RO UND O F THE INVENTION

This invention relates to systems for parking automobiles or storing similar articles, and more particularly to an automatic or semi-automatic system that meets the demands for parking facilities for high density, small ground area requirements such as exist in locales of factories, hotels and condominiums. In order to be a practical solution to this specific parking problem it must be a modular, easily erected system preferably demountable for land use change purposes. These constraints lead to a modular, abutting square tubing structural framework held in place by quasi-tubular corner connectors, and a simple layout of left and right storage stalls on each tier, with an elevator or hoist in the center having a transfer mechanism thereon, for storage and retrieval. For larger throughput volumes, a more complex system such as that described in patent No. 3,984,012, to the same inventors, would be required for economic feasibility, rather than providing additional parallel facilities of the invention, since the present system is best suited to implementation in 10, 20, or 40 stall structures having only a left and right stall on each tier. The simplicity of the layout is the largest contributor to the high operating speed of the instant invention.

SUMMARY OF THE INVENTION It is the primary object of the invention to provide a parking facility that is faster than any existing system in its storage and retrieval cycles.

It is another object of the invention to provide a system that can be oriented vertically, occupying minimal space in crowded areas.

It is another object of the invention to provide a system that consists of modular tiers so that it can be erected in a relatively short time.

It is another object of the invention to provide a simplified system that can be operated by unskilled personnel, or can be entirely automated.

Another object of the invention is to provide a system that is adaptable so that a single basic design can be used in a plurality of facility applications and sizes.

Yet another object of the invention is to provide a structure that is demountable for application to temporary facilities as would be required for sports events, fairs, and military installations.

Another object of the invention is to provide a storage and retrieval system that is energy conserving since only the weight of a single automobile is moved in a storage or retrieval cycle, while others remain stationary. It is another object of the invention to eliminate the necessity for large braking loads as in the stopping of a plurality of vehicle masses in a ferris wheel configuration.

The units to be stored must be placed on a pallet which conforms to the size and shape of the device to be stored, whether it be an automobile, a machine, a container, or a combination of discrete devices, and is adapted to retain it on the pallet during storage as well as during transfer motions. The mechanism for transferring pallets must occupy minimal space' and be simple, reliable and low in power consumption. These constraints on the transfer mechanism led to the two sequential movement transfer mechanism which engages sprocket racks, one near each end of each pallet, by a vertically disposed chain loop on each end of the transfer mechanism. Initially, the chain loop carriage is moved by a rack and pinion a distance of about 16 inches for engagement with the pallet rack in a retrieval sequence, for example, and then the chain drive is energized to complete a transfer of a pallet. A single motor and clutch mechanism controls this sequence from electrical control signals. Since simple left-right transfer motions are all that are required, a simple switch controlled sequence is practical, in combination with indicator lights indicating the tier level and stall occupancy, observable at the entry level. An operator can actuate appropriate switches to effect a storage or retrieval cycle. Alternatively, the entire system can be automated using simple controllers, readily available, so that no operator is required to be in attendance. The unique transfer mechanism, in combination with the architectural design provides the optimum system for application to the relatively small capacity but ubiquitous parking problem as well as for storage of other devices

BRIEF DESCRIPTON OF THE DRAWINGS Figure 1 is an isometric drawing of a portion of the vertically oriented high-rise modular structure illustrating the abutting square tube frame and corner connector neibers, and the location of the tiers in each nodule. Figure 2 is a detail drawing of the corner connector.

Figure 3 is a section view of the first level on which upper level modules are stacked, illustrating the foundation scheme and frame crossbracing. Figure 4 is a floor plan view of the first level illustrating the entry and departure directions, the elevator mechanism compartment, the safety doors, and elevator bottom containing a pallet thereon.

Figure 5 is an isometric drawing of the elevator cage illustrating the lift scheme and showing roller bearings which constrain the cage in the vertical channels in longitudinal and transverse directions.

Figures 6, 7, and 8, are top, bottom, and side views, respectively, of a pallet which receives an automobile f or storage in a stall on a tier.

Figures 9, 10, 11, and 12, are detail drawings illustrating the constraining bearings and channels for the elvator cage in the vertical quad-channel elevator shaft.

Figure 13 is a plan view of the transfer mechanism which shifts a pallet which sets on it, in the elevator cage, to or from a storage stall.

Figure 14 is an end view of a transfer assembly illustrating the elevator cage mounted transfer assembly engagement with a pallet.

Figure 15 is an isometric detail drawing of one of the two transfer assemblies, without the chain, for clarity.

Figure 16 is a cross sectional view through the drive gears for the first sequential transfer movement.

Figure 17 is an end view of the transfer mechanism illustrating the self supporting chain loop wherein each chain link pin has rollers on each end for holding the chain flat against the pallet sprocket rack along its length.

Figure 18 is a sequential schematic drawing of the transfer sequence for storage and retrieval.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Reference is directed to Figure 1. The novel modular structure is shown in isometric view, the first tier structure being substantially of well known construction, including a footing of poured concrete with square tube vertical columns extending into caissons which provide support. The square tube columns 11, 12, 13, 14 at the corners of the structure extend to the first modular corner connectors 15, 16, 17, (and 18, not shown), and include horizontal beams 19, 20, 21, 22, and cross braces from corner to corner consisting of clevises, rods, and turnbuckles, well known in the art as a cross bracing means. The first tier structure includes stall pallet rails 23, 23A, 24 (and 24A not in view) which attach to beams 20, 22, by welded tabs extending therefrom, the pallet rail e.g. 23, is higher than rail 23A for drainage of moisture toward beam 19 and to provide an incline to prevent an automobile from rolling in reverse direction. The first two-tier module consists of horizontal beams 25, 26, 27, 28; vertical columns 29, 30, 31 (and 32 not in view); corner connectors e.g., 33, 34, and pallet rails e.g., 23, 24. Elements of this two-tier structural module are produced in standard units In a factory for shipment to the site where the units are hoisted and assembled to form the modules. Modules are stacked to provide the required number of tiers. The top of each vertical corner column has a plate 50 (Figure 2) against which each next higher corner column bears to provide a thrust bearing surface such that the load of the top tier is transmitted to the bottom through the intervening modules. The corner connector retains the vertical columns and horizontal beams at their junctions. by bolt means. Wide flange beams 35, 36, 37, and 38, (Fig. 1) form the elevator cage guide rails. These elevator cage guide rails are independent of the modules and extend from the top tier down to the caissons.

Figure 2 shows the corner connector which consists of angle irons 41, 42, orthogonal tube sections e.g., 43, 44, 21, 22 (Fig 1) and cross bracing tabs 45, 46, 47, gle irons fit on the outside of the vertical columns at the junctions thereof such as 11/29 (Fig. 1) and are retained in place by bolts extending therethrough. The thrust bearing plate 50, which is the covered end of the lower column assures that the bearing load is distributed over the cross sectional area of the vertical columns. The plate 50 is welded to the top of each column.

Figure 3 shows the first four tiers in sectional view and illustrates the footing and cross bracing as well as the elevator shaft rails, e.g. , 35, 38, extending to the caissons, e.g. , 53, 52 respectively, and corner columns e.g., 11, 14, extending into caissons 51, 54, respectively. Cross braces using well known means are illustrated in the figure for completeness. The footing 55 shall be reinforced formed concrete The roof and siding for the modular structure are of well known structural design and materials and are not part of the novel combination of this invention. Figure 4 is a plan view of the entry level which shows in more detail the plan of the entry level and indicates in dotted line, the position of an automobile on the elevator cage on which is stacked the transfer mechanism and pallet in that order. For example, in a system employing an attendant, a parking sequence is as follows:

The sliding gates 57 on the driver's side are open.

The siding gates 56 on the passenger's side are open.

The entry door 58 is open.

The exit door 59 is closed. The elevator cage, with a pallet 60 from a stall, e.g., tier 1 Left is at the entry level.

The driver enters the facility, driving onto the pallet until the front wheels reach the wheel stops on the pallet.

The automobile is braked; the driver and the passengers leave the automobile.

An attendant activates the gate closing mechanism; the gates 56, 57, close.

The attendant presents a claim check to the driver. The claim check identifies the destination stall (e.g., 1L).

The driver and passengers depart through the personnel doors

61, 62.

The attendant activates the storage sequence. The storage sequence is as follows:

The entry door 58 closes.

Sensors determine that the two doors and the two sliding gates are closed. The elevator rises to the level (1L) where the empty stall is located.

The transfer mechanism transfers the pallet into the empty stall (1L).

When the transfer is complete, the transfer mechanism transfers the empty pallet from the stall (1R) on the other side of the hoistway, onto the elevator, assuming that pallet is empty.

If the pallet on the opposite side is not empty, the elevator rises to the nearest level where an empty pallet is located and transfers that pallet onto the elevator.

The elevator proceeds to the entry level. When the elevator arrives at the entry level, the entry door 58 opens and the sliding gates 56, 57 open.

The system is ready to receive the next automobile. The retrieval of a vehicle is on a random basis and conditions in the system will vary. In the sequence below, the driver of a vehicle in stall 1L, for example, arrives to retrieve his vehicle. For illustration purposes, assume that at the entry level there is an empty pallet (6R) from a previous retrieval. The following conditions exist:

The sliding gates 56, 57, are open.

The entry door 58 is closed. The exit door 59 is open.

The elevator with the pallet from the empty stall (6R) is at the entry level.

When the driver presents the claim check to the attendant, the attendant activates the retrieval sequence.

The exit door 59 closes.

The sliding gates 56, 57 are closed.

Sensors determine that the two doors and the two sliding gates are closed. The elevator rises to the level (6R) where the empty stall is located.

The transfer mechanism transfers the pallet into stall (6R).

When the transfer is complete the elevator goes to storage level 1. The transfer mechanism transfers the pallet from stall 1L to the elevator.

The elevator proceeds to the entry level.

When the elevator arrives at the entry level, the exit door opens, the wheel stop locks are retracted, and the sliding gates open. The automobile can now be exited.

What happens next depends on whether a storage sequence or a retrieval sequence is required. If a new arrival appears,

The exit door 59 closes and wheel stops rise into place.

The entry door opens. The system is ready to receive the vehicle.

If departure of a vehicle is required,

The exit door 59 closes.

The sliding gates 56, 57 close. The elevator goes to the stall (1L). The pallet is transferred into stall 1L The elevator waits for instructions as to which pallet to retrieve. Figure 5 is included to show the configuration of the vertically movable, restrained elevator cage and illustrate the hoisting means as well as the roller bearings which restrict its position inside the hoistway created by the vertical beams 35, 36, 37, and 38 (Fig. 1). Not shown are safety braking systems well known in the art, which can be installed to make the elevator system fail safe.

Figures 6, 7, and 8 are top, bottom, and side views of a pallet showing the elongated sprocket racks 71, 72, wheel lateral restrainers 73, 74, and circumferentially grooved rollers, e.g.. 75, 76. See inset for an enlarged view of a grooved roller which rides on a rail, e.g., 24, (Fig.1) at each end of each stall.

Figure 9 shows an end view of the elevator cage 40 with the pallet 60 and transfer mechanism 70 mounted thereon. Figure 10 illustrates the means for restraining the elevator cage 40 in the hoistway formed by wide flange beams 35, 36, 37, and 38 (Fig. 1). Figure 11 gives detail of the transverse direction restraining means, showing, for example, cage 40 roller 79 in contact with I-channel 35, and above it, (Figure 12) for longitudinal restraint, roller 78 contained by the parallel tapered walls of I-channel 35. Figure 13 shows the drive means of the transfer mechanism 70, consisting of bidirectional motor 81 which drives a pinion gear in each of the two transfer assemblies 80, 80A through the reduction gear box 82. The rack and pinion 89, 91 (Fig 15) of transfer assemblies 80, 80A, (Fig 15) are actuated through shafts 85, 86. Sprocket 92 (Fig. 15) is activated in the opposite direction through reduction gear box 83 and drive shafts 87, 88. Referring now to Figure 14, sprocket 92 moves chain 90 at twice the speed that rack 89 moves. Rack 89 is attached to movable frame 94 (Fig. 15) which is extended about 16 inches to the left for example. When the movable frame is fully extended, clutch brake 84 (Fig 13) is activated and bidirectional motor 81 is stopped and reversed. This causes the movable frame to be locked in the extended position and chain 90 to reverse its direction. The chain is engaged with the elongated sprocket rack 71 (Fig 7) for example on one end of the pallet 60 and the motion of the chain causes the pallet to move into the stall. It will be noted from Figure 14 dotted line that the chain drive assembly shifts either left or right with the pallet since fixed frame 93 (Fig. 16) on which the movable frame 94 of the transfer assemblies 80, 80A is movable on rollers, e.g., 95, Figure 17.

Figures 16 and 17 also show a novel feature of the chain 90. It is supported between sprockets on the level frames 94, 101, by rollers, e.g., 96,97, on the extended ends of the link pins e.g., 98. Referring back to Figure 14, the chain loop 90 is formed by idler sprocket wheels e.g., 99 to optimally engage the sprocket rack 71 on the pallet 60. This is also true of transfer assembly 80A and rack 72 on pallet 60. Figure 18 A, B, C, d, illustrate the sequence of the transfer mechanism in a storage cycle, while E, F, G, and H show the sequence for a retrieval cycle. Assuming that there would be a vehicle on the pallet, the vehicle would be stored in a stall following these steps:

A. The elevator approaches the designated tier stall and stops.

B. The transfer mechanism rack and pinion is energized in a counterclockwise direction and the chain drive is energized in a clockwise direction at twice the speed of the rack so that the movable frame moves to the left about 16 inches carrying the chain loop with it.

C. The rack and pinion drive is de-energized and locked in place, and the motor rotation is reversed. The chain drive is energized in a counterclockwise direction and the chain loop moves the pallet to the left into the stall.

D. When the pallet is completely in the stall, the rack and pinion is activated in a clockwise direction by the clutch, the chain drive continues to rotate and the movable frame is returned to the original position.

In a retrieval sequence:

E. The elevator returns to the stall from which a vehicle is to be retrieved, without a pallet.

F. The rack and pinion drive and the sprocket drive are energized to move the movable frame to the left so that the chain loops begin to engage the pallet in the stall. The rack and pinion is locked in place and the chain drive is reversed and the chain loop pulls the pallet to the right.

G. This action is continued until the pallet is shifted to the right limit stop.

H. This chain drive is reversed and the rack and pinion drive is energized to center the movable frame under the pallet.

It is apparent that these sequences can be automatically controlled by readily available system controller devices with programming capability or interactive capability. Herein has been described a preferred embodiment of the invention, and the best mode of operation. It is apparent that variations, substitutions and modifications of the elements thereof will readily occur to those skilled in the art, and it is intene claims be interpreted as encompassing all equivalents thereof.

WHAT IS CLAIMED IS:

Claims

1. In a storage and retrieval system of the type wherein an elevator, centrally located among a plurality of stalls on a plurality of tiers, moves an automobile, positioned on a pallet, to a designated tier, and a transfer means moves the pallet from the elevator into one of the plurality of stalls on that tier for storage, and subsequently retrieves the pallet from the stall and places it on an elevator for movement to a departure level, the improvement which comprises: an elevator having first, second, third, and fourth vertical channels at the corners of a horizontal rectangle, defining an elevator shaft, said channels being substantially u-shaped, having a base and orthogonal side walls; and an elevator cage, substantially rectangular, having left and right sides and front and back ends, top and bottom, and having longitudinal and transverse axes, movable vertically in said vertical channels; and motor means connected to said elevator cage for moving said cage in said channels; restraining means on said elevator cage left and right sides and front and back ends, in contact with said first, second, third and fourth vertical channels for restraining said elevator cage in said elevator shaft along said longitudinal and transverse axes; a plurality of tier frames vertically coextensive with said elevator shaft, said frames having first, second, third, and fourth vertical columns, first, second, third. and fourth horizontal beams, and first, second, third and fourth corner connectors, said plurality of tier frames being stackable modules, one on top of another at said vertical columns; first and second pairs of rails extending from said vertical channels to said modular tiers first and third horizontal beams on the left side and the right side of said elevator cage respectively, defining stalls in said modular tiers, said rails connected to said second and said fourth horizontal beams; transfer means on said elevator cage adapted to move said pallet from said elevator cage to said stalls along said first or said second pair of rails and back; control means connected to said elevator motor means and to said transfer means for controlling the time of activation thereof; whereby a pallet on said transfer means on said elevator cage can be moved by said transfer means either to the right or the left side of said elevator cage onto said pair of rails into a stall in said tier frame, and be retrieved therefrom, in minimum time.

2. In a storage and retrieval system of the type wherein an elevator, centrally located among a plurality of stalls on a plurality of tiers, moves an automobile, positioned on a pallet, to a designated tier and a transfer means moves the pallet from the elevator into one of the plurality of stalls on that tier for storage, and subsequently retrieves the pallet from the stall and places it on an elevator for movement to a departure level, the improvement which comprises: an elevator having first, second third and fourth vertical channels at the corners of a horizontal rectangle, defining an elevator shaft and an elevator cage movable vertically in said e levator shaft; a plurality of tier frames vertically coextensive with said elevator shaft, said frames having first, second, third, and fourth vertical columns, first second third and fourth horizontal beams, and first, second, third, and fourth corner connectors, said plurality of tier frames being stackable modules, one on top of another at said vertical columns; first and second pairs of rails extending substantially horizontally from said vertical channels to said modular tiers horizontal beams on the left side and the right side of said elevator cage respectively, defining stalls in said modular tiers; whereby a pallet can be moved by said transfer means either to the right or the left side of said elevator cage onto said pair of rails into a stall in said tier frame, and be retrieved in minimum time.

3. A storage and retrieval system as described in claim 1 wherein said modular tier frame further comprises: a first square tube section vertical column having a closed end and an open end and four corners, said first square tube adapted to but against a lower square tube section closed end at a junction thereof; a first horizontal beam having first and second angle irons oriented transversely at the ends thereof, said angle irons being one half of a corner connector at each end of said horizontal beam, said angle iron adapted to butt against a first corner of said square tube column at a junction thereof; a second beam, horizontally disposed, having first andsecond angle irons oriented transversely at the ends thereof, said angle irons being second halves of two corner connectors at each end of said horizontal beam, said angle iron adapted to butt against a corner opposite said first corner of said square tube at a junction thereof; a second, third, and fourth vertical column section at the corners of a frame; third and fourth horizontal beams having corner connectors zadapted to interfit against opposite corners of said second, third and fourth vertical columns at the junctions thereof; retaining means adapted to clamp said first and beam angle irons together at the junction of said vertical column sections; whereby said vertical column square tube sections butt against a lower tier module at a junction and are restrained from horizontal misalignment by said corner connector while transmitting vertical loads through module column sections, from topmost section to the bottom.

4. A storage and retrieval system as described in claim 3 wherein said retaining means consists of at least two bolts extending through bores in said corner connector angle irons and said abutting vertical column sections near the junctions, and nut means for clamping force, on said bolts.

5. A storage and retrieval system as described in claim 1 wherein said transfer means comprises: a stationary frame mounted in said elevator cage at the bottom, said frame having first and second ends; first and second movable frames near said stationary frame first and second ends, movably mounted on said stationary frame and having a rack gear on the bottom and a chain loop carried by said movable frame on a plurality of idler sprockets; a rack and pinion drive means in engagement with said rack gear, said drive means mounted on said stationary frame: a sprocket and chain drive means engaging said chain loop, said drive means mounted on said stationary frame; whereby in moving a pallet, the first and second movable frames move the chain loop to engage the sprocket racks on a pallet, and subsequently the chain loop is rotated, moving the sprocket on the pallet onto the chain loop.

6. A storage and retrieval system as described in claim 1 wherein said pallet further comprises: a base, substantially rectangular, having top, bottom, and front, back, left, and right sides, and a longitudinal axis; a first channel member mounted on said base on the top, near the left side, said channel adapted to receive the left wheels of an automobile retaining them transversely of said pallet base longitudinal axis; a second channel member mounted on said base on the top near the right side, said channel adapted to receive the right wheels of an automobile said second channel being wider than said first channel to accommodate automobiles of various sizes; stop means in said first and second channels adapted to retn the left and right front wheels of said automobile on said pallet along the longitudinal direction, said stop means being releasable by latch means on said elevator cage; first and second sprocket racks extending transversely of said base, on the bottom thereof, near the front and back sides respectively; whereby said first and said second sprocket racks are engaged by said first and said second transfer means loop chains on said movable frames, and said first and said second channels provide structural rigidity to said pallet.

7. A storage and retrieval system as described in claim 5 wherein said chain loop further comprises: a plurality of vertically disposed idler sprockets in engagement with said loop chain, mounted on said movable frame, said loop chain having links and pins connecting said links, said link pins being longer then said links width, said pins having first and second ends; first and second rollers on said link pin ends; and a drive sprocket engaging said chain loop; whereby said chain loop is self supporting over a large span when the link pins roll on a flat surface on said fixed frame and on said movable frame for engagement with said pallet sprocket rack .

8. A storage and retrieval system as described in claim 5 wherein said control means further comprises: a bidirectional motor for driving said rack and pinion drive means and said sprocket and chain drive means; a sensor in each of said stalls adapted to sense the presence of a pallet in each of said stalls; an elevator hoisting motor; sensor means detecting elevator tier level; a clutch connected to said bidirectional motor, said rack and pinion drive means, and said sprocket and chain drive means for energizing one or the other of said drive means or both simultaneously; identification switch means designating a stall in a tier; a controller for controlling said bidirectional motor, said rack and pinion drive means, said sprocket and chain drive means, and said clutch means, in accordance with said elevator level sensing means, said sensor in each of said stalls and said identification switch means designating a stall location; whereby the stall occupancy indicated by said sensors controls the time of activation of said elevator motor, said bidirectional motor, said clutch, said rack and pinion drive means, and said sprocket and chain drive means.

9. A storage and retrieval system as described in claim 1 wherein said restraini for said elevator cage comprises: orthogonally disposed rollers attached to said elevator cage at the top left side, front and back , top right side, front and back, bottom left side front and back and bottom right side front and back, said orthogonally disposed rollers adapted to roll against said first, second, third, and fourth substantially u-shaped channels, at the base and at the orthogonal walls thereof, restraining said elevator cage along said longitudinal and transverse axes, whereby structural channels may be used as an elevator shaft to contain an elevator cage.

10. A storage and retrieval system as described in claim 8 wherein said controller is a microprocessor.

11. A storage and retrieval system as described in claim 7 wherein said controller is manually operated in response to said sensor signals.

12. A transfer mechanism for transferring pallets having zsprocket means attached thereto for engagement with a chain drive which moves the pallet relative to the chain loop location along the plane of the chain loop, the improvement which comprises:

a stationary frame having a longitudinal axis; a movable frame, having top, bottom, first and second sides, said frame movably mounted on said stationary frame transversely of said longitudinal axis, said movable frame having a rack gear on the bottom, and a plurality of idler sprockets on said first side and roller means mounted on said first and second sides adapted to roll on said fixed frame; a chain loop engaging said idler sprockets, extending along said first side of said movable frame; a rack and pinion drive means in engagement with said rack gear on the bottom of said movable frame, said drive means mounted on said stationary frame; a sprocket and chain drive means engaging said chain loop, said drive means mounted on said stationary frame; control means connected to said rack and pinion drive means and to said sprocket and chain drive means, said control means adapted to move said rack on the bottom of said movable frame in one direction or the other a fixed distance to position said chain loop and then activate said sprocket and chain drive means in sequence; whereby the movable frame is positioned to engage the pallet sprocket with the transfer mechanism chain and then rotate the chain loop to move the pallet in one direction or the opposite, the transfer mechanism being adapted to occupy minimal space in a zstorage structure.