WO2012055410A2

WO2012055410A2 - Robot and storage facility

Info

Publication number: WO2012055410A2
Application number: PCT/DK2011/000122
Authority: WO
Inventors: Claus Bagger
Original assignee: Inventnord Aps
Priority date: 2010-10-29
Filing date: 2011-10-28
Publication date: 2012-05-03
Also published as: WO2012055410A3

Abstract

Inventory retrieval system on command, comprising: - a main computer system handling input and generating control output to the inventory retrieval system; - one or more substantially identical containers arranged in - at least one container storage/holding facility, in which the containers are arranged in one or more linear arrays; - a robot device arranged on one or more guideways for travel along the linear array(s); wherein the robot device has means for lowering connection means down into a container positioned under the robot, where said connection means connect and elevate an object stored in said container from said container and transfers the object to conveying means arranged in parallel to said array of containers, where said conveying means transports the object to further processing.

Description

Robot and storage facility Field of the Invention

The present invention concerns an inventory retrieval system on command as well as a method for retrieving predetermined objects from a storage facility containing a plurality of various objects.

Background of the Invention

In the art it is well-known to create storage facilities where robots may collect goods automatically from predefined positions. Usually these storage facilities are arranged with the goods in a high number of tiers, i.e. layers of goods arranged on top of each other and next to each other. The robot will travel down guideways between the storage shelves and engage the goods stored in a specific position and bring it to the handling bay. Usually the goods will be palletized such that the robot will collect an entire pallet comprising a large number of objects. Where it is desirable to retrieve single objects in a random order these types of systems are not suitable.

Traditionally, picking single objects in random order is performed by personnel being equipped with a list of items to be picked; they will then move around the storage fa- cility and collect the necessary items.

This is both a costly and time-consuming manner, and furthermore as the items are collected they are usually collected a few objects/items at a time where specific identification papers are applied to each item such that during the actual packaging and for- warding of each item this unique identification label has to be removed so that it can be checked that it corresponds to the address on the packaging label.

Furthermore as picking is performed manually a rather large floor area is required, which usually is rather expensive.

These prior art systems are therefore very expensive, usually relatively space consuming and are prone to shipping the wrong objects to the wrong customers. It is therefore an object of the present invention to provide a fully automatic system which will be able to select and pick a predetermined object in random order from a large storage facility comprising different types of objects.

Object of the Invention

The invention addresses this by providing an inventory retrieval system on command comprising:

- a main computer system handling input and generating control output to the inventory retrieval system;

- one or more substantially identical containers arranged in

- at least one container storage/holding facility, in which the containers are arranged in one or more linear arrays;

- a robot device arranged on one or more guide ways for travel along the linear array(s); wherein

- the robot device has means for lowering connection means down into a container positioned under the robot, where said connection means connect and elevate an object stored in said container from said container and transfers the object to conveying means arranged in parallel to said array of containers, where said conveying means transports the object to further processing. By providing a robot which can enter a container in which an object is stored and connect with the object in order to remove it from the container and place it on conveying means the entire retrieval system is atomized, whereby the possibility of human error potential is reduced. It is also possible to pick single objects/items instead of entire pallets or the like.

As the robot travels along or above the conveying means, a single conveying means in cooperation with a single robot may serve an entire array of containers, and in this manner a very simple, economically viable and reliable system is provided. The conveying means may advantageously be connected to the same applicant's prior, but not yet published international patent application, PCT/DK2010/050240, which is a a device for packaging three-dimensional objects in envelopes such that a completely automatic retrieval and packaging system is provided by these two apparatuses.

With this combination no human interference is needed from the order is entered in the computer system until the item is packaged and delivered to the distribution service, such as for example the postal services.

In a still further advantageous embodiment of the invention each container's position is associated with a unique set of position coordinates, stored in a host computer, and where the number of objects in each container is registered in said host computer, and furthermore where the host computer will generate an output signal specific for a particular container, when a predetermined number of objects has been collected from said container. With these means it is possible for a single central computer to keep track of the activities going on in the retrieval system and the stock of each item/object stored in each single container. Furthermore, by being able to generate an alarm, i.e. an input signal indicating that a container is running out of objects, maintenance service may be carried out before the retrieval system shuts down such that substantially continuous operation of the system may be achieved.

As all objects are placed on one single conveyor, they will arrive at the unloading end of the conveying means in the order they where placed on the conveyor and therefore also in the order that the robot was ordered to pick a specific object. In this manner it is relatively easy to keep track of the position of the objects placed on the conveying means such that further packaging and shipping may be carried out very reliably due to the easy identification of each object entering an unloading zone on the conveying means. In a still further advantageous embodiment of the invention the robot device comprises first and second guide beams arranged perpendicularly to each other on a main frame structure, wherein the first beam is arranged vertically, where a travelling unit is arranged for vertical travel along said first beam, where said unit has first engagement means for engaging objects in the container, and where the second guide beam is provided with second engagement means for engaging objects elevated from the container by said first engagement means, where said second engagement means are arranged for travel along said second beam, and where means are provided for selectively dis- engaging the engagement means at desired positions.

In a further embodiment the robot device comprises a guide beam arranged perpendicularly to a horizontal plane, where a travelling unit is arranged for vertical travel along said beam, where said unit has an arm comprising engagement means for engag- ing objects in the container, and where said arm is pivotable relative to the guide beam, such that the arm at least may be pivoted into a first position superposed the object to be collected and a second position superposed the conveying means.

By being able to pivot the arm, transfer between various parts of the robot of the object is avoided. Although it is easier to control linear movements, the pivotable arm provides a simpler mechanical and thereby cheaper construction. Furthermore the pivotable arm reduces the number of engagement means (as only one device is griping the object between collection in the container and delivery on the conveyor). By means of this simple robot in principle comprising two movable parts, i.e. a first movable part travelling vertically and a second movable part travelling horizontally, it is possible to lift an object from a container, transfer it to the second movable part which will move it horizontally into a position superposed the conveying means and deliver the object under the conveying means. By providing a relatively simple robot the control of the movements is easy to programme and the movement of the units travelling on the guidebeams may be relatively fast such that a high production rate is achieved. Furthermore the construction is relatively simple, reliable and mechanically servicefriendly. For a number of purposes it is advantageous that the engagement means are one or more suction cups in that the wrapping or packaging of objects is typically done with relatively closed surfaces such that suction cups may adhere to the objects also where the objects are not completely plane, but for example have a curvature such as balls and and the like.

In a still further advantageous embodiment of the invention the containers comprise a bottom, and a number of side walls upstanding from the periphery of said bottom, where a slit is provided in a side wall, said slit connects to the free end of the sidewall opposite the bottom.

The provision of the slit facilitates that the robot may enter the container from a side surface instead of from the open top and as such the robot may be directed along the side surface onto objects placed at the bottom of the container. A further advantage of the slit is the fact that it is relatively easy by visual means to detect whether or not objects are present in the container and thereby check that the input deriving from the robot and the computer-system is correct. Furthermore, the containers may in addition to the slit be provided with side-walls in a transparent material such that it is possible visually to inspect the contents of each container and furthermore visually check that the engagement means of the robot connects properly to objects stored in the container such that a reliable collection of objects in accordance with the orders entered into the system via the main computer is in fact carried out. To this end the engagement means or the robot may be provided with object detection means as disclosed in a further advantageous embodiment where the connection means comprise means for positively determining that an object is attached to the connection means, where said means is selected from any one or a combination of the following: an electrical micro-switch, a photocell or other optical means, a con- ductive sensor.

In a still further advantageous embodiment of the invention the retrieval system is provided with two container storage/holding facilities arranged in parallel where the one or more guideways and common conveying means are arranged between the two container storage/holding facilities, and where a second robot device is arranged on the one or more guideways for travel along the linear array(s), where also the second robot device has means for lowering connection means down into a container positioned under the second robot, where said connection means connect and elevate an object stored in said stored in said container from said container and transfers the object to conveying means arranged in parallel to said array of containers.

In this manner a space saving installation is achieved especially due to the fact that the conveying means may be maintained at a speed which can serve two robots. Also this feature is utilized in order to improve the overall economics of the system. As the system is controlled by a computer, it is relatively easy for the operator to detect when one or more containers need to be replenished. In a still further advantageous embodiment two container storage/holding facilities are arranged in parallel at the same level, and that a plurality of levels are provided on top of each other, each level having two container storage/holding facilities arranged in parallel, and that a common robot is provided for the system, where said robot is provided with second guide beams for each container storage/holding facility at each level, and that a chute is provided for each level above the lowermost level, where said chute allows objects collected at a particular level by means of the chute to be placed on the conveying means.

As the system may operate substantially automatically, i.e. without manpower, it is possible to make a space saving installation and as furthermore floor space is an important and expensive parameter a multilevel storage facility providing a system where additional levels are provided, utilize the floor space to the largest extent possible. This is possible, as it is not necessary for manpower to be able to access the entire installation. Only when containers need to be manually handled, i.e. replaced or re- plenished, is it necessary for personnel to gain access. For this purpose bridges may be provided between the adjacent arrays as long as these bridges do not interfere with the chutes which allow objects from a higher level to be displaced towards the conveying means due to the influence of gravity or by for example endless belts mounted in the chutes. The mainframe structure may be designed as will be elaborated further below with reference to the detailed embodiment in such a manner that the access bridges may be accommodated between the arrays or alternatively access to containers in upper levels may be gained from either side of the system. In a still further advantageous embodiment the connection means comprise a unit, being extendable and retractable between a rest position in which the unit is above the upper rim of the containers in the array, and an extended position where the unit is in contact with an object to be collected stored in a container.

These connection means is an alternative to the connection means described above with the beam structure in that for some applications it might be advantageous to have extendable/retractable means for example in the shape of a telescope such that containers without a slit in the side may also be accessed. This is particularly useful for small objects in that for these types of products it may be undesirable to have a slit in the side of the container.

The invention in a further embodiment comprises containers made from a transparent material, and that visual means are arranged near the connection means for detecting if the container is empty, where said visual means comprises means for communicating the status of a particular container to the main computer system.

The transparency of the containers allows for visual detection means to "see" into the container. This is also facilitated by the slit in the container. For example when using a laser device, the laser is programmed to register any block of the beam within a certain distance. If the container is empty, the transparent material will allow the laser beam to shoot through the container, thereby registering that the container is empty, and forward the appropriate input to the main computer.

An alternative is the use of a video camera coupled to recognition software. This is especially advantageous where the objects in the various containers have different shapes, and where the objects do not fill the entire bottom area of the container. In this connection the laser detection is highly reliable as long as the objects cover approx. half the area of the container's bottom. In order to indicate an empty container the invention in a further embodiment provides the robot device with an extendable pushing device, which when a container is empty is activated in order to push the container out of the linear array. In this manner an easily detectable manner is provided when a container needs to be replaced or refilled.

The invention is also directed at a method of operating an inventory retrieval system on command as described above where an order comprising a unique object identification code is entered into the systems' main computer system, where said unique code is translated to a particular position in the system corresponding to the position of one specific container in an array of substantially identical containers, in which container objects corresponding to the unique object identification code are stored, where the main computer generates an output to a robot arranged for travel parallel to the array of containers, such that the robot will travel to the desired container, where said robot has means for connecting and collecting an object from the desired container, and placing said object on a conveying means, for further processing of said object.

Description of the Drawing

The invention will now be described with reference to a particular embodiment with reference to the accompanying drawing wherein

Figure 1 illustrates a perspective view of part of an inventory retrieval system on command according to the invention

Figure 2 illustrates the same inventory system, but seen from the front

Figures 3-4 illustrate the robot means in more detail

Figures 5-8 illustrated the transport of objects from the container to the "drop position" superposed the chute

Fig. 9-13 illustrate a further embodiment having a pivotable arm

Fig. 14 illustrate a container pushing device

Detailed Description of the Invention

In figure 1 is illustrated a perspective view of part of an inventory retrieval system on command according to the invention. In this embodiment the system has two levels 10, 1 1 where each level 10, 1 1 comprises two container storage/holding facilities 1, 2 where substantially identical containers 3 (illustrated as transparent containers) are arranged in a single linear array in each holding facility. The container storage/holding facility 1, 2 each comprises a main frame 20 having cross-members 21 providing support for the substantially identical containers. In the embodiment depicted in figure 1 the distance between the members 20 and the cross-members 21 is such that two substantially identical containers may be accommodated transverse to the longitudinal direction of the array. However, only one container is illustrated and no containers are indicated in the second position.

Each container is assigned a specific unique position such that the robot device may be able to travel and engage objects in that particular container due to its specific location and knowledge in the system of that specific location.

In this instance the robot is mounted on a common mainframe structure 5. Four robot devices 12, 13, 14 and 15 are arranged on the common mainframe structure 5. The mainframe structure 5 may travel along the container storage handling facilities 1 , 2 in a manner such that the robots 12, 13, 14, 15 may access any container positioned in any of the arrays.

In the illustrated example objects 30 are positioned in a transparent container adjacent the mainframe 5, and furthermore an object 31 has been collected from the container and transferred to the second engagement means 42 arranged on the second guidebeam means 41.

As the object 31 is released from the engagement means 42, the object 31 will by means of the chute 50 be guided onto conveying means 51 for transport out of the inventory retrieval system for further processing.

In this embodiment the chute 50 is fixed to the mainframe 5 in such a manner that the chute will travel along the guideways together with the four robot devices (12,13,14,15) in such a manner that the two upper robots 12, 13 will be able to deliver objects as illustrated by object 31 to the chute and thereby transferring the object 31 to the common conveyor means 51, whereas the lower robots 14,15 will deliver objects directly to the conveyor 51. In this manner a single mainframe comprising four robots and one conveying means will be able to service a very large number of containers 3. In figure 2 is illustrated the same inventory system, but seen from the front.

Four arrays of identical containers 3 are arranged in two levels 10, 11 where each level is provided with two robots 12, 13, 14, 15 such that engagement means on each robot 12, 13, 14, 15 may engage objects placed in the containers 3. The robots are arranged on a mainframe 5 which by means of guideways 52, 53 allows the mainframe to travel back and forth along the arrays of containers 3. The chute 50 as already explained above allows objects to slide down the chute and be placed on the conveying means on this embodiment indicated as an endless belt 51.

Turning to figure 3 and 4 the robot means are illustrated in more detail. In all the figures like elements are provided with like reference numbers. In the illustrated detailed example the connection means are only illustrated as suction cups 31 , but it is clear that other appropriate means may be used in order to engage the objects 30 placed in the containers 3. In the present example the suction cups 31 are furthermore provided with a resilient member in order to provide a substantially airtight connection and thereby a safer and more reliable contact with the flat surface of the objects 30. The robots 12, 13, 14, 15 each comprise a first vertical beam member 32, see figure 4, with a travelling unit 33 arranged for travel along said first beam member 32. In this manner it is possible to position the first engagement means 34 both in the positions illustrated with reference to figure 4 where the engagement means are just about to engage an object 30 in a container 3 as well as in a position as illustrated with reference to figure 3 where the engagement member 34 has been elevated to a position above the container.

As an object 30 is elevated by the first connection means 34 to a position above the container 3, the second connection means 42 mounted for travel along a second beam 41 will be activated, and the object 30 will be transferred from the first engagement means 34 to the second engagement means 42 mounted on the second guidebeam 41. In this manner it is possible to first elevate the object vertically out of the container and after transferring to the second guidebeam member and the second engagement member member 42 transport the object substantially horizontally until it is superposed the chute 50 in which position (as depicted in figure 1) the engagement means 42 disengages from the object which will then drop onto the chute and slide to the conveying means 51 as illustrated in figure 3.

This transport of objects from the container 3 to the "drop position" superposed the chute is illustrated with reference to figures 5-8.

In figure 5 the first engagement means 34 have engaged and elevated an object 30 partly up through the container 3. As the elevation continues, the object 30 will be brought into contact as illustrated with reference to figure 6 with the second engagement means 42 and at the same time or soon after be released by the first engagement means 34 such that the object is now carried by the second engagement means 42. The object will then travel along the second beam 41 as illustrated in figure 7 into a position superposed the chute as illustrated in figure 8. In this position the second engagement means 42 will release the object 30 which will then slide down the chute 50 and onto the conveying means (not illustrated).

Although not illustrated the robot will naturally be supplied with the necessary wiring and circuitry in order to respond to the input signals received from the main computer such that the computer will be able to travel along the guideways and place the engagement means 34, 42 in appropriate positions relative to the desired objects stored in relevant containers. As may be determined from figure 1 , 4-6, the containers are transparent and provided with a slit 39 such that the first engagement means 34 may reach through the wall of the container and thereby be able to place the suction cups in contact with the object 30.

In the embodiment as illustrated with reference to fig. 9-13, the construction of the system is as already described above with reference to fig. 1, i.e. the system has a number of levels 10,1 1 where containers 3 are arranged in linear rays on each level. In this embodiment a single robot device 60 is arranged between the two container storage/holding facilities 1,2. The robot device 60 may travel on rails 61 along the storage/holding facilities 1,2. The robot device 60 comprises a vertical beam or column 62 which is provided with rails 63 such that the robot device 60 may travel on the rails 61. Furthermore, a pivotable arm 64 is arranged on the column 62 such that the arm may move up and down relative to the column whereby the arm may be brought into positions, for example as illustrated with reference to fig. 9 where the arm is superposed a container 3 at any level. The pivotable arm 64 is provided with engagement means 65 in the shape of suction cups such that as the robot arm is lowered into the container 3 as illustrated with reference to fig. 10 the engagement means 65 will come into contact with an object 30 stored in the container 3 such that the vacuum in the suction cups constitute the engagement means 65 and will adhere to the object 30 such that any movements of the pivotable arm also will cause the object to move.

In fig. 9 the pivotable arm and in particular the engagement means 65 have been superposed an object 30 placed in a container 3. The exact position of the robot device 60 and thereby the engagement means 65 is decided by input received from at central computer relating to that particular product as already discussed above. Typically, the products may be CDs, DVDs computer games, books, medicine doses, contact lenses, etc.

In fig. 10 the pivotable arm has been lowered by allowing the arm to travel on the column 62 until the engagement means 65 adheres to the object 30. In fig. 11 the pivotable arm 64 has been raised such that the engagement means and the object are above the upper rim of the container. In this position it is possible to pivote the pivotable arm 64 into a position as illustrated with reference to fig. 12 where the pivotable arm is aligned with the conveyor 51. In this position the pivotable arm will travel down the column 62 in order to deliver the object 30 on to the conveyor as illustrated with reference to fig. 13. When the object 30 is delivered on to the conveyor 51 the object 30 may be transported to further processing, for example packaging etc. After having delivered the object to a conveyor 51 the pivotable arm 64 and the entire robot device 60 are ready to collect the next item. Turning back to fig. 11 the pivotable arm is positioned superposed the container 3. At the bottom of the container 3 an object is still present. A visual detecting device 67 in the shape of a laser program to detect reflections within 25-35 centimetres is positioned such that as an item 30 is elevated from the container 3 it will investigate whether or not further objects 30' are present in the container. If the light is reflected an object is present and no further action is taken. On the other hand if the container is empty as is the case with the container 3' on the opposite side of the robot device 60, the robot device 60 will send this information to the main computer such that action may be taken in order to either refill the container 3' or place a new full container in the correct position. It is also possible that a number of containers in a ray 10,11 may contain the same objects such that the next time a specific object is to be picked and placed on the conveyor 51 the computer will instruct the robot to pick from a different location.

In the illustrated embodiment the visual detection device 67 is a laser beam, but also other means may be used such as for example a video camera with object recognition software which will, in principle in the same manner as described above with respect to a laser device, detect/recognize objects in the container.

Turn into fig. 14 an extendable pushing device 70 is illustrated. The extendable pushing device 70 may also be recognised in any of the fig. 9-13.

The extendable pushing device 70 is in this embodiment constructed by making use of a piston rod 71 actuated by a cylinder 72 such that as an empty container 3' is registered in the system the computer system instructs the extendable pushing device to extend the piston 71 and thereby moving the empty container 3' out of a ray of containers 3 and thereby clearly indicating that action needs to be taken with respect to this particular container 3'. The extendable pushing device is mounted on the column 62 of the robot device 50 such that, in the same movement where the visual detection device 67 detects an empty container 3', the extendable pushing device may be positioned such that the piston 71 may engage the empty container 3'.

Claims

1. Inventory retrieval system on command, comprising:

- one or more substantially identical containers arranged in

the robot device has means for lowering connection means down into a container positioned under the robot, where said connection means connect and elevate an object stored in said container from said container and transfers the object to conveying means arranged in parallel to said array of containers, where said con- veying means transports the object to further processing.

2. Inventory retrieval system on command according to claim 1, wherein each container's position is associated with a unique set of position coordinates, stored in a host computer, and where the number of objects in each container is registered in said host computer, and furthermore where the host computer will generate an output signal specific for a particular container, when a predetermined number of objects has been collected from said container.

3. Inventory retrieval system on command according to claim 1, characterised in that the robot device comprises first and second guide beams arranged perpendicularly to each other on a main frame structure, wherein the first beam is arranged vertically, where a travelling unit is arranged for vertical travel along said first beam, where said unit has first engagement means for engaging objects in the container, and where the second guide beam is provided with second engagement means for engaging objects elevated from the container by said first engagement means, where said second engagement means are arranged for travel along said second beam, and where means are provided for selectively disengaging the engagement means at desired positions.

4. Inventory retrieval system on command according to claim 1, characterised in that the robot device comprises a guide beam arranged perpendicularly to a horizontal plane, where a travelling unit is arranged for vertical travel along said beam, where said unit has an arm comprising engagement means for engaging objects in the container, and where said arm is pivotable relative to the guide beam, such that the arm at least may be pivoted into a first position superposed the object to be collected and a second position superposed the conveying means.

5. Inventory retrieval system on command according to claim 1 or 3, characterised in that the engagement means are one or more suction cups.

6. Inventory retrieval system on command according to claim 1, where the containers comprise a bottom, and a number of side walls upstanding from the periphery of said bottom, where a slit is provided in a side wall, said slit connects to the free end of the sidewall opposite the bottom.

7. Inventory retrieval system on command according to any preceding claim characterised in that two container storage/holding facilities are arranged in parallel, where the one or more guideways and common conveying means are arranged between the two container storage/holding facilities, and where either a second robot device is arranged on the one or more guideways for travel along the linear array(s), where also the second robot device has means for lowering connection means down into a container positioned under the second robot, or where said arm may pivot into positions superposed objects arranged in any position in the holding facility, and a position superposed the conveying means, where said connection means connect and elevate an object stored in said container from said container and transfers the object to conveying means arranged in parallel to said array of containers.

8. Inventory retrieval system on command according to claim 1 characterised in that two container storage/holding facilities are arranged in parallel at the same level, and that a plurality of levels are provided on top of each other, each level having two container storage/holding facilities arranged in parallel, and that a common robot is pro- vided for the system, where said robot either is provided with second guide beams for each container storage/holding facility at each level, and that a chute is provided for each level above the lowermost level, where said chute allows objects collected at a particular level by means of the chute to be placed on the conveying means or where said arm may pivot into positions superposed objects arranged in any position in the holding facility, and a position superposed the conveying means.

9. Inventory retrieval system on command according to claim 7 or 8, characterised in that the robots are arranged on the same main frame structure, and optionally that a plurality of main frame structures are arranged for travel along the same guide- ways.

10. Inventory retrieval system on command according to claim 1, characterised in that the connection means comprises means for positively determining that an object is attached to the connection means, where said means is selected from any one or a combination of the following: an electrical micro-switch, a photocell or other optical means, a conductive sensor.

11. Inventory retrieval system on command according to claim 1 , characterised in that the containers are made from a transparent material, and that visual means are arranged near the connection means for detecting if the container is empty, where said visual means comprises means for communicating the status of a particular container to the main computer system.

12. Inventory retrieval system on command according to claim 1, characterised in that the robot device comprises an extendable pushing device, which when a container is empty is activated in order to push the container out of the linear array.

13. Method of operating an inventory retrieval system on command according to any of claims 1 to 12 wherein an order comprising a unique object identification code is entered into the systems' main computer system, where said unique code is translated to a particular position in the system corresponding to the position of one specific container in an array of substantially identical containers, in which container objects corre-

jects corresponding to the unique object identification code are stored, where the main computer generates an output to a robot arranged for travel parallel to the array of containers, such that the robot will travel to the desired container, where said robot has means for connecting and collecting an object from the desired container, and placing said object on a conveying means, for further processing of said object.