WO2009118100A1

WO2009118100A1 - Automated system for picking up and handling goods in warehouses, and associated method

Info

Publication number: WO2009118100A1
Application number: PCT/EP2009/001769
Authority: WO
Inventors: Marco Brogi
Original assignee: Bromas S.R.L.
Priority date: 2008-03-26
Filing date: 2009-03-12
Publication date: 2009-10-01
Also published as: ITTO20080226A1

Abstract

An automated system for picking up, handling, and moving goods (27) around in warehouses, the system including a truck (21) with devices (22) for horizontal movement of the truck, which is able to move autonomously without the aid of fixed or mobile mechanical guide means that do not form part of the truck (21) itself. The truck (21) possesses handling devices (26, 29) for moving goods, which are designed to enable goods (27) to be picked up and subsequently repositioned in the warehouse. The system (20) moreover possesses guide means (23) fixed to a structure (24) inside said warehouse; the guide means (23) are designed to guide vertical movement of the handling devices (26, 29) for moving goods.

Description

AUTOMATED SYSTEM FOR PICKING UP AND HANDLING GOODS IN WAREHOUSES, AND ASSOCIATED METHOD

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The present invention relates to a system for handling goods in warehouses. In detail, the present invention refers to an automated system for picking up and moving goods around in warehouses, and to the associated method.

In large firms or wherever there ftx-i st the need for storing and subsequently removing even partially large amounts of goods, there has been a consolidation of technologies for mechanized management of the warehouse, which are able to reduce the expenses in terms of labour force and at the same time increase and speed up the operations of handling and movement of the goods themselves .

Known to the art are systems for picking up and handling goods by means of trucks moved by mechanical -driving means. In this case, the truck is moved in an automatic way along a path defined, for example, by one or more metal guides. An example of this latter type of system is described in Figure 1, which illustrates a system 1 for handling goods, in which a truck 2 is made to translate on a metal guide 3, for example, by means of an electronic control managed in real time by a user. This control acts on an electric motor 4, which is fixed to the truck 2 and meshes on a metal guide 3 in such a way as to exert a friction sufficient to displace the truck 2 even under the weight of the goods loaded thereon.

The metal guide 3 is i-ypically fixed in α rigid way on the floor (for example, by means of anchor bolts or via other known techniques) and develops along a given path inside a warehouse. In detail, the truck 2 envisages a portal structure 5, positioned within which is a support 6 for loading and unloading the goods, which can be raised for at least part of the height of the portal structure 5.

In detail, during the operation of loading and unloading of the goods 8, a pair of forks (not illustrated) present on the support 6 is inserted into a pallet 7, which lies on one or more supporting structures 9 raised with respect to the floor or ground and forming part of a modular storage system

10, on which the set of goods 8 to be displaced is positioned.

At this point, the support 6 is raised sufficiently so as to enable detachment of the pallet 7 from the supporting structures 9. Then the forks are retracted in such a way as to set the pallet substantially in a central position on the support 6 of the truck 2. At this point, it is possible to lower the support 6 and proceed with movement of the truck 2 from the warehouse to a cpnt-rp for sorting the gccdc (net illustrated) , in which the pallet 7 is typically extracted from the support 6 with a reverse procedure with respect to the loading procedure.

Systems of this type, i.e., provided with a guide fixed to the ground, present various drawbacks.

In the first place, they are not flexible, and any possible changes in the arrangement of the modular storage system 10 cause enormous expenses even for repositioning of the metal guides.

In the second place, the aisles for access between adjacent modular storage systems 10 cannot be traversed by traditional systems for handling and moving goods, such as, for example, motor-driven fork-lift trucks, precisely on account of the presence of the metal guides 3 , which hence oppose an insurmountable obstacle for said means. In particular, in the case where the warehouse presents a checkerboard geometry, it is moreover difficult to manage two metal guides set orthogonal to and intersecting one another, in so far as there could arise, in the areas of intersection, dangers of the truck coming off the guide.

In addition, the metal guide 3 must envisage ™.ear.c for electrification to enable operation of the electric motor 4. Clearly, a guide of an electrified type is dangerous, in so far as, if it is not perfectly insulated, it may cause hazardous leakage current to ground (for example, in the case where immediately adjacent to the guide there is the formation of pools of water) or electric discharges of considerably high energy, given that the trucks 2 are typically driven by high voltages.

Alternatively, it is possible to use power supply cables, which, however, also may undergo possible failure or get cut and which moreover must be as long as the entire path followed by the truck 2 along the metal guide 3 and consequently would frequently not be compliant with current safety standards. Finally, it is possible to use battery-supplied trucks 2. It is, however, necessary to bring the metal guide 3 as far as into a position compatible with recharging or replacement of the batteries, with consequent further increase in the expense for installation of the system.

Likewise, a truck 2 driven along a single metal guide 3 is rather unstable and, in the case wherp it has to carry goods of considerable weight at a great height (the portal structures 5 can reach and exceed thirty metres in height) , upon loading of the goods there is the risk of generating a twisting torque on the metal guide 3 such as to deform it or even such as to cause detachment of the truck 2 from the guide, a fact that is unacceptable especially in the case where the goods to be handled are either precious or dangerous . Even though there exist movable trucks which also use a top guide (for example, the guide 3b in Figure 1) , said solution does not in any case solve the problem of impracticability of the aisles and of the poor flexibility to changes in logistics of the warehouse.

In addition, providing installation of a top guide is moreover economically expensive.

Finally, a truck for storage systems that moves on a guide has just one degree of freedom. Consequently, it is not able to deviate from the path of the guide itself, but simply to move backwards and forwards with respect thereto. Consequently, its capabilities of displacement are considerably reduced.

The purpose of the present invention is to provide an automated system for picking up and handling gccds in warehouses and the associated method, which will be free from the drawbacks described above .

Provided according to the invention are an automated system for picking up and handling goods in warehouses and the associated method as specified in

Claim 1 and Claim 16, respectively.

The invention will now be described with reference to the annexed drawings, which illustrate a non-limiting example of embodiment and in which:

- Figure 1 is a three-dimensional view of a system for handling goods in a warehouse;

- Figure 2 is a three-dimensional view of a preferred embodiment of an automated system for picking up and handling goods in a warehouse by means of a truck according to the present invention;

- Figure 3 illustrates a perspective detail , of a guide for raising a surface for supporting goods of the system illustrated in Figure 2;

Figure 4 illustrates a perspective detail of a means for raising the surface for supporting goods of Figure 3 ;

- Figure 5 illustrates an operating condition of the system of Figure 2 in which the raiding means ol Figure 4 is coupled to the raising guide of Figure 2; and

Figure 6 to 12 illustrate steps during time evolution of an action of picking up goods inside a warehouse by means of the system of Figure 2. With reference to Figure 2, designated as a whole by 20 is an automated system for picking up and handling goods in warehouses, which comprises, in the first place, a self-propelled truck 21 equipped with devices for horizontal movement of the truck, such as wheels 22 (also of a steering type) or tracks 22', and a plurality of raising guides 23, which are designed to be firmly constrained to a modular structure 24 in a substantially vertical direction. In detail, the truck 21 is moved automatically and is not constrained by a path defined by metal guides. Consequently, in this way, an aisle 25 present between two modular structures 24 may always be traversed also by the traditional means for handling goods, such as motor-driven fork-lift trucks. Present on the truck 21 are supports 26 for loading and unloading goods 27 typically contained in boxes or packages which are positioned on pallets 28 made, for example, of wooden material or else are arranged on supporting surfaces forming part of the modular structure 24.

The truck 21 comprises inside it one or more energy accumulators, which are able to supply at least one electric motor, which enables displacement thereof. Precisely on account of the presence of wheels 22 also of a steering type, the truck 21 has two degrees of freedom of movement and is able to operate even in aisles that present bends without any need for metal guides for horizontal movement. The truck 21 comprises one or more connection modules 29, which are arranged at the front and rear ends and enable - in particular operating conditions described in greater detail hereinafter - a plurality of engaging devices 30 to be constrained on the raising guides 23.

In particular, according to the weight of the goods 27 to be transported, the truck 21 can be equipped with: a single module 29 in the front or rear part; or else two modules 29, set, respectively at the front and at the rear.

The embodiment of the invention represented in the figures illustrates a solution in which the truck 21 is moved on wheels.

In greater detail, each module 29 is set in a direction substantially orthogonal to the direction of advance of the truck 21 and comprises two extendable arms 29a, 29b, each having two ends of which a first one remains positioned substantially inside the module 29, whilst a second one is connected to the respective engaging device 30 and extends outside the module 29 itself. The engaging device 30 is designed to mesh on the raising guide 23 (Figure 3) , which is typically made of high-strength metal or plastic material and is provided with a plurality of fixing means (for example, but without this constituting any limitation, holes 31 designed to enable passage of screws) for firm connection with the modular structure 24. The raising guides 23 can be superimposed on standard uprights present on the modular structure 24. Precisely for this reason the system according to the present invention is highly compatible with multiple types of modular structures 24, even ones installed prior to installation of the system according to the invention.

In detail, the raising guides 23 further comprise a plurality of meshing means 32 extending along a rectilinear path designed to enable the engaging device 30 to move on the raising guide 23 itself without any possibility of slipping.

The meshing means 32 are constituted by a plurality of through holes; alternatively, they may even have a shape with ("tooth-like") projections so as to guarantee meshing. In any case, the meshing means 32 of the guides 23 extend preferably in a direction parallel to that of maximum length of the guides 23, as illustrated, for example, in Figure 3.

As is shown in Figure 4, in use the engaging device

30 meshes on the meshing means 32 through a plurality of teeth 33 arranged on the links of a chain 34, which is connected to at least one driving gear wheel

35, which is designed to force movement of the chain

34.

In this way, it is possible to cause pr-nrjression of the engaging device 30 in a direction substantially the same as the one in which the meshing means 32 extend .

Preferably, the chain 34 is made to form an endless loop, and the part of chain 34 that in use has its teeth 35 constrained to the meshing means 32 is separated, on the opposite side, by a structure 36, in such a way as to prevent any possible slackening of the chain 34 from causing seizing or jamming of the gear wheel 35.

The gear wheel 35 may be driven, for example, by an electric motor or by a hydraulic system. For example, in the case where an electric motor is used, it is easy to obtain variation of the speed of rotation of the toothed wheel 35 and, in the case where the truck has to lift particularly heavy goods 27, there is the guarantee of having the maximum possible torque precisely upon starting of rotation of the gear wheel. In fact, it is known how electric motors generate -the maximum torque of rotation at an extremely low r.p.m. of their drive shaft. As is shown in Figure 5, in use, when the goods 27 are to be picked up or positioned in the respective place in the warehouse, the truck 21 must be positioned in such a way as to cause alignment of the engaging devices 30 with the respective raising guide 23.

The truck 21, in fact, contains inside it memory means, which are able to know beforehand the route to follow inside the warehouse, as well as where to stop .

Consequently, the truck 21 can be programmed beforehand from a computer connected thereto via radio, i.e., through a wireless connection, or, alternatively, with a programming cable. Following upon alignment of the engaging devices 30 with the respective raising guide, extension of the extendable arms 29a, 29b is performed for a length such as to constrain the teeth 33 of the chain 34 with the meshing means 32 of the raising guides 23. According to a first embodiment of the invention, in order to pick up the set of goods 27 from the warehouse, in the first place the truck must set itself in such a way as to align the engaging devices 30 to the raising guides 23 (see Figure 6, which represents a front view of the trunk ?i, positicr.ed in the aisle 25) that are fixed to the modular structure 24.

Next (Figure 7) , the extendable arms 29a, 29b of the modules 29 are extended until it is possible for the teeth 33 of the chain 34 to mesh with the meshing means 32.

At this point, by means of a elevating mechanism 39, the support 26 is raised to a height substantially- corresponding to that of the pallet 28 of the set of goods that it is intended to pick up.

In detail, the elevating mechanism 39, schematically represented in Figures 7 and 8 with a spiralled structure, can be, by way of non-limiting example, a hydraulic piston the fluid of which is sent under pressure by an electric pump or a pump powered by an explosion engine or else be a system equipped with chains or pantographs .

Hence, adopting a known technique, the pallet 28 containing the set of goods 27 is picked up. In detail, according to the first embodiment of the invention, this operation envisages moving the support 26, here comprising forks 40, until said forks position themselves underneath the pallet 2S for a length sufficient to enable raising thereof. Next, the support 26 is raised slightly, in such a way as to lift the pallet 28 from the warehouse structure, and then the forks 40 are retracted in such a way as to set the pallet 28 in a position substantially centred on the truck 21 itself, as is shown in Figure 9.

Next, as is represented in Figure 10, the elevating mechanism 39 is lowered to a height h such as not to create danger during movement of the truck 21 reducing the height of the centroid of the truck- goods ensemble and, preferably, is lowered until the minimum possible height is reached.

During the step of lowering of the elevating mechanism 39, the engaging devices 30 remain connected to the raising guides 23. In this way, there is guaranteed a greater stability of the goods

27 and there is further prevented the possible advance or recession of the truck 21 during the step of lowering of the raising system 39.

According to whether, during lowering, the elevating mechanism 39 has to reach the position at height h or the minimum possible height, at this point (Figure

11) the engaging devices are disconnected from the raising guides 23, and the extendable arms 29a, 29b are made to return into the respective modules 29.

Finally, as illustrated in Figure 12, the truck 21 is at this point ready to advance inside the aisle 25 with the set of goods 27 loaded thereon in the direction of destination of said goods 27.

Clearly, in order to put the goods 27 back in the original position, it is necessary to follow the reverse procedure .

Using the system so far described it is hence possible, in the case where it is intended to pick up not all the goods 27 present on the pallet 28, but only a part thereof, to proceed automatically to picking up the set of goods 27 from the warehouse, to sending said goods 27 by means of the truck 21 to the user, and, following upon picking-up of the amount of goods necessary, repositioning the pallet 28 in its original position.

A second embodiment of the invention differs from the one previously described on account of the absence of the forks 40 on the support 26.

In detail, the forks 40 can be replaced by movable or anthropomorphic arms provided, for example, with grippers or other complex systems.

This can be particularly useful in the case where the system is employed in warehouses in which it is necessary to pick up goods 27 of very small dimensions and set in boxes of small dimensions or stored as bulk material .

Using the system described so far, the only intervention by the user is hence, in use, programming of the position of the goods 27 to be picked up inside the warehouse. Consequently, the time dedicated to moving of the truck 21, once the logistics of the warehouse has been stored inside the memory of the truck 21, is convenient and guarantees a minimal expenditure of time.

Finally, in the case where the goods 27 are particularly heavy or the height at which they are to be picked up is considerable, the truck 21 can be equipped with a suspension system, once again of an automatic type, able to balance it and to correct any possible rolling or pitching in the case where the load is unevenly displaced. In this case, the automatic suspension system maintains the supporting surface as orthogonal as possible to the line of the force of gravity, in such a way as to prevent any dangerous sliding of the goods.

This solution enables, for example, safe movement of the truck 21 even in conditions of uneven ground or countering of the squeezing of the tyres, in the case where the wheels 21 are of a tyred type, and is particularly useful for balancing, for example, the truck 21 when the pallet 28 is being picked up. In fact, at said instant the supports 26 are completely outside the overall dimensions of the truck 21 and unbalance it in a non-indifferent way. The advantages of the present invention are hence clear from the foregoing description. In particular, by means of the automated system for picking up, handling and moving goods around in warehouses described so far, it is possible to pick up and reposition in an automatic way at least part of the set of goods contained on one or more pallets by- means of a self-propelled truck without mechanic guides fixed on the ground or to the structure of the warehouse itself in such a way as to guarantee always accessibility to the aisles of the warehouse in the case, for example, where the truck breaks down. In this case, the traditional means for lifting goods, such as, for example, motor-driven fork-lift trucks, have no trouble in travelling along the aisles of the warehouse, hence preventing any interruption of the activity of transportation, picking-up, and repositioning of the goods in such a way as not to jeopardize activity of the warehouse itself. In addition, the absence of metal guides guarantees a considerable flexibility of the system described even in the case of variation in the logistics of the warehouse. In fact, it is not necessary to dismantle fixed structures anchored to the ground, but simply reprogram the logistics of the warehouse on the memory of the truck.

The system described is moreover intrinsically stable since the raising platform is constrained - by means of the engaging devices - to the structure of the warehouse on both sides of the truck, and consequently, even with heavy loads, the risk of goods being spilt or the truck overturning is considerably reduced.

Some variations may be applied to the system described so far. For example, the raising guides can have a shape different from the one described and can likewise present two or more rows of parallel teeth or holes for connection to the teeth of the chain. In addition, the engaging devices can have one or more driving gear wheels or be equipped with a number of chains .

Finally, the engaging devices themselves can be without any chain and have a gear wheel directly meshing on holes or teeth present on the raising guides 32.

Claims

1. An automated system (20) for picking up, handling, and moving goods (27) around in warehouses, the system comprising:

- a truck (21) equipped with devices (22, 22') for horizontal movement of the truck, which' is able to move autonomously without the aid of fixed or mobile mechanical guide means that do not form part of the truck (21) itself; and guide means (23) fixed to a structure (24) inside said warehouse; said truck (21) comprising handling devices (26, 29) for moving goods, which are designed to enable said goods (27) to be picked up and subsequently repositioned in the warehouse, the system (20) being characterized in that said guide means (23) are designed to guide the vertical movement of said handling devices (26, 29) for moving goods.

2. The system according to Claim 1, wherein said handling devices (26, 29) for moving goods comprise at least one handling module (29) and at least one support (26) for loading and unloading said goods (27) .

3. The system according to Claim 2, wherein said each handling module (29) comprises two telescopic arms

(29a, 29b) designed to extend outside said handling module (29) ; there being mounted on a respective end of said telescopic arms (29a, 29b) an engaging device (30) designed to connect up in use to said guide means (23) .

4. The system according to Claim 3, wherein said telescopic arms (29a, 29b) are designed to extend outside the respective handling module (29) up to the point where said engaging devices C*n) ccir.c into contact with said guide means (23) .

5. The system according to Claim 3 , wherein the engaging device (30) comprises at least one chain (34) provided with a plurality of teeth (33) and is designed, in use, to mesh on said meshing means (32) arranged on said guide means (23) by means of said plurality of teeth (33) .

6. The system according to Claim 3, wherein the engaging device (30) comprises a gear wheel (35) , which meshes directly on said meshing means (32) .

7. The system according to Claim 1, wherein said devices for horizontal movement of the truck are wheels (22) or tracks (22') .

8. The system according to Claim 5, wherein said chain (34) is connected to at least one driving gear wheel (35) mounted on said engaging device (30) .

9. The system according to Claim 5, wherein said meshing means (32) are teeth or holes arranged in one or more rows in a substantially rectilinear direction and extending in a direction of maximum length of said guide means (23) .

10. The system according to Claim 1, wherein said truck (21) further c.nmpr±ses lifting αr.d loweriny devices (39) designed to enable substantially vertical movement of said handling devices (26, 29) for moving goods .

11. The system according to Claim 1, wherein said truck (21) comprises one or more energy accumulators, which are able to supply at least one electric motor that enables displacement of said truck (21) .

12. The system according to Claim 1, wherein said truck (21) is provided with storage means, stored inside which are paths inside the warehouse; said truck (21) being programmable for reaching a set of goods (27) and/or picking up said set of goods (27) and/or repositioning said set of goods (27) inside the warehouse .

13. The system according to Claim 1, wherein said support (26) for loading and unloading of said goods

(27) comprises a fork (40) for movement of pallets

(28) on which said set of goods (27) is positioned.

14. The system according to Claim 1, wherein said support (26) comprises pluriarticulated mechanical arms designed to pick up said goods (27) .

15. The system according to Claim 1, equipped with automatic means for countering roll -ing and pitching, which are designed to offset the possible oscillations of said support (26) during advance of the truck (21) or during a step of picking-up of said goods (27) from said structure (24) .

16. A method for handling goods in an automated system (20) for picking up, handling, and moving goods (27) around in warehouses, said method comprising the steps of: automated movement of a truck (21) for reaching an area of the warehouse in which the set of goods (27) to be picked up is present; and picking-up of the set of goods (27) from or positioning thereof in said warehouse; the method being characterized in that said step of picking-up or positioning of the set of goods (27) comprises, in order of time: setting of the truck (21) in a position corresponding to a plurality of guide means (23) fixed to the structure of the warehouse;

- lifting and/or lowering of one or more handling devices (26, 29) for moving goods, which comprise at least one handling module (29) and at least one support (26) for loadinq and unloading cf said goods (27) .

17. The method according to Claim 16, wherein between the step of positioning of the truck (21) and the step of lifting and/or lowering of said handling devices (26, 29) for moving goods, there is an extension of telescopic arms (29a, 29b) towards the outside of the respective module (29) up to the point where engaging devices (30) , positioned on said telescopic arms (29a, 29b) , come into contact with said guide means (23) .

18. The method according to Claim 17, wherein said telescopic arms (29a, 29b) are retracted only following upon lowering of the handling devices (26, 29) for moving goods to a pre-set height.

19. The method according to Claim 18, wherein said telescopic arms (29a, 29b) are retracted only- following upon lowering of the handling devices (26, 29) for moving goods to a minimum possible height.