WO2023170167A1 - Système de commande - Google Patents

Système de commande Download PDF

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Publication number
WO2023170167A1
WO2023170167A1 PCT/EP2023/055919 EP2023055919W WO2023170167A1 WO 2023170167 A1 WO2023170167 A1 WO 2023170167A1 EP 2023055919 W EP2023055919 W EP 2023055919W WO 2023170167 A1 WO2023170167 A1 WO 2023170167A1
Authority
WO
WIPO (PCT)
Prior art keywords
safety
grid
robots
communication system
bot
Prior art date
Application number
PCT/EP2023/055919
Other languages
English (en)
Inventor
Christopher ROFF
Kyriakos ORFANAKOS
Parth AMIN
Mohsin SHEIKH
Robert RODDIS
Mark England
Original Assignee
Ocado Innovation Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ocado Innovation Limited filed Critical Ocado Innovation Limited
Publication of WO2023170167A1 publication Critical patent/WO2023170167A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
    • B65G1/02—Storage devices
    • B65G1/04—Storage devices mechanical
    • B65G1/137—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed
    • B65G1/1373—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed for fulfilling orders in warehouses
    • B65G1/1375—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed for fulfilling orders in warehouses the orders being assembled on a commissioning stacker-crane or truck
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
    • B65G1/02—Storage devices
    • B65G1/04—Storage devices mechanical
    • B65G1/0407—Storage devices mechanical using stacker cranes
    • B65G1/0414—Storage devices mechanical using stacker cranes provided with satellite cars adapted to travel in storage racks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
    • B65G1/02—Storage devices
    • B65G1/04—Storage devices mechanical
    • B65G1/06—Storage devices mechanical with means for presenting articles for removal at predetermined position or level
    • B65G1/065—Storage devices mechanical with means for presenting articles for removal at predetermined position or level with self propelled cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
    • B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
    • B65G43/06—Control devices, e.g. for safety, warning or fault-correcting interrupting the drive in case of driving element breakage; Braking or stopping loose load-carriers

Definitions

  • the disclosure relates to relates to a communications system, and in particular to a communications system for use with robots in a warehouse facility.
  • Grid-based automatic storage and retrieval systems are well known in the art.
  • a plurality of robotic load handlers operate on a horizontal grid structure, underneath which is received a plurality of containers, arranged in a plurality of stacks.
  • the containers are used to hold products and the load handlers are adapted to retrieve containers from one of the plurality of stacks and to deposit a container within one of the stacks.
  • the load handlers may be routed in an autonomous manner (or a semi- autonomous manner) on the grid but a wireless communications system is required to transmit instructions to load handlers and to enable each of the load handlers to communicate with a management system.
  • the claimed apparatus, methods, systems and computer programs are intended to provide improvements relating to communications systems for use in an automated retrieval and storage system which uses a fleet of robotic load handlers
  • a communication system for a warehouse facility with robots comprising: one or more base stations; a plurality of robots configured to move around a grid within the warehouse facility and perform operations, wherein each of the plurality of robots comprise a network interface such that a data signal can be transmitted from a base station to each of the plurality of robots, the data signal comprising; a) a plurality of low bandwidth communication links; b) one or more high bandwidth communication links; and c) a safety signal.
  • Each of the plurality of robots may be uniquely associated with a low bandwidth communication link such that one or more instructions may be transmitted to a robot using the associated low bandwidth communication link.
  • the warehouse facility may comprise a plurality of grids such that each of the plurality of grids has a respective plurality of robots configured to move upon it.
  • the safety signal may comprise an identifier which identifies one or more of the plurality of robots and a safety command which is applicable to the one or more identified robots.
  • a safety command which is applicable to one or more of the plurality of robots is executed in preference to the one or more instructions received by the robots via the associated low bandwidth communication link.
  • the safety signal identifier may comprise a grid identifier such that the safety signal safety command is applicable to the plurality of robots moving on the one or more grids associated with the grid identifier.
  • the safety command may cause the one or more identified bots to stop operating.
  • the communication system may further comprise a plurality of safety elements wherein, in use, a safety signal is generated in response to the activation of a safety element.
  • the communication system may further comprise one or more safety transmitters wherein, in use, the activation of a safety element is received by a safety transmitter such that the safety signal can be generated by the safety transmitter.
  • the communication system may comprise one safety transmitter for each of the one or more grids within the warehouse facility. The or each safety transmitter may be uniquely associated with one of the one or more grids within the warehouse facility.
  • a method of operating a plurality of robots comprising the steps of transmitting a data signal from a base station to each of the plurality of robots, the data signal comprising; a) a plurality of low bandwidth communication links; b) one or more high bandwidth communication links; and c) a safety signal.
  • a data carrier device comprising computer executable code for performing the method described above.
  • a storage system comprising: a first set of parallel tracks extending in an X-direction, and a second set of parallel tracks extending in a Y-direction transverse to the first set in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces; a plurality of stacks of storage containers located beneath the tracks, and arranged such that each stack is located within a footprint of a single grid space; at least one transporting device, the at least one transporting device being arranged to selectively move in the X and/or Y directions, above the stacks on the tracks and arranged to transport a storage container; a picking station arranged to receive a storage container transported by the at least one transporting device and to transfer an item from the storage container into a delivery container; and a communication system as described above.
  • the at least one transporting device may have a footprint that occupies only a single grid space in the storage system, such that a transporting device occupying one grid space does not obstruct a transporting device occupying or traversing the adjacent grid spaces in the X and/or Y directions
  • Figure 1 schematically illustrates a storage structure and containers
  • Figure 2 schematically illustrates track on top of the storage structure illustrated in Figure 1 ;
  • Figure 3 schematically illustrates load-handling devices on top of the storage structure illustrated in Figure 1 ;
  • Figure 4 schematically illustrates a single load-handling device with containerlifting means in a lowered configuration
  • Figure 5 schematically illustrates cutaway views of a single load-handling device with container-lifting means in a raised and a lowered configuration
  • Figure 6 shows a schematic depiction of an automated storage and retrieval system
  • FIG. 7 shows a schematic depiction of the grid controller
  • Figure 8 shows a schematic depiction of a part of the automated storage and retrieval system of Figure 6;
  • Figure 9 shows a schematic depiction of a bot in relation to the reception and processing of the signal transmitted by the base station
  • Figure 10 shows a schematic depiction of a safety signal and a method by which it is processed by a bot
  • Figure 11 shows a first example of the structure of the frames that are used in the communications system
  • Figure 12 shows a schematic depiction of the structure of a downlink subframe that is used in the communications system
  • Figure 13 shows a schematic depiction of the structure of an uplink subframe that is used in the communications system
  • Figure 14 shows a schematic depiction of a simplified view of a part of the communications system of Figure 6;
  • Figure 15 shows a graphical depiction of the method by which safety signals are transmitted and processed.
  • Figure 16 shows a schematic depiction of a computer device 1600 used in the implementation of a communications system of the present disclosure.
  • Figure 1 illustrates a storage structure 1 comprising upright members 3 and horizontal members 5, 7 which are supported by the upright members 3.
  • the horizontal members 5 extend parallel to one another and the illustrated x-axis.
  • the horizontal members 7 extend parallel to one another and the illustrated y-axis, and transversely to the horizontal members 5.
  • the upright members 3 extend parallel to one another and the illustrated z-axis, and transversely to the horizontal members 5, 7.
  • the horizontal members 5, 7 form a grid pattern defining a plurality of grid cells.
  • containers 9 are arranged in stacks 11 beneath the grid cells defined by the grid pattern, one stack 11 of containers 9 per grid cell.
  • Figure 2 shows a large-scale plan view of a section of track structure 13 forming part of the storage structure 1 illustrated in Figure 1 and located on top of the horizontal members 5, 7 of the storage structure 1 illustrated in Figure 1.
  • the track structure 13 may be provided by the horizontal members 5, 7 themselves (e.g. formed in or on the surfaces of the horizontal members 5, 7) or by one or more additional components mounted on top of the horizontal members 5, 7.
  • the illustrated track structure 13 comprises x-direction tracks 17 and y-direction tracks 19, i.e. a first set of tracks 17 which extend in the x-direction and a second set of tracks 19 which extend in the y- direction, transverse to the tracks 17 in the first set of tracks 17.
  • the tracks 17, 19 define apertures 15 at the centres of the grid cells.
  • the apertures 15 are sized to allow containers 9 located beneath the grid cells to be lifted and lowered through the apertures 15.
  • the x-direction tracks 17 are provided in pairs separated by channels 21
  • the y-direction tracks 19 are provided in pairs separated by channels 23. Other arrangements of track structure may also be possible.
  • FIG 3 shows a plurality of load-handling devices 31 moving on top of the storage structure 1 illustrated in Figure 1.
  • the load-handling devices 31 which may also be referred to as robots 31 or bots 31 , are provided with sets of wheels to engage with corresponding x- or y-direction tracks 17, 19 to enable the bots 31 to travel across the track structure 13 and reach specific grid cells.
  • the illustrated pairs of tracks 17, 19 separated by channels 21 , 23 allow bots 31 to occupy (or pass one another on) neighbouring grid cells without colliding with one another.
  • a bot 31 comprises a body 33 in or on which are mounted one or more components which enable the bot 31 to perform its intended functions. These functions may include moving across the storage structure 1 on the track structure 13 and raising or lowering containers 9 (e.g. from or to stacks 11 ) so that the bot 31 can retrieve or deposit containers 9 in specific locations defined by the grid pattern.
  • the illustrated bot 31 comprises first and second sets of wheels 35, 37 which are mounted on the body 33 of the bot 31 and enable the bot 31 to move in the x- and y- directions along the tracks 17 and 19, respectively.
  • two wheels 35 are provided on the shorter side of the bot 31 visible in Figure 4, and a further two wheels 35 are provided on the opposite shorter side of the bot 31 (side and further two wheels 35 not visible in Figure 4).
  • the wheels 35 engage with tracks 17 and are rotatably mounted on the body 33 of the bot 31 to allow the bot 31 to move along the tracks 17.
  • two wheels 37 are provided on the longer side of the bot 31 visible in Figure 4, and a further two wheels 37 are provided on the opposite longer side of the bot 31 (side and further two wheels 37 not visible in Figure 4).
  • the wheels 37 engage with tracks 19 and are rotatably mounted on the body 33 of the bot 31 to allow the bot 31 to move along the tracks 19.
  • the bot 31 also comprises container-lifting means 39 configured to raise and lower containers 9.
  • the illustrated container-lifting means 39 comprises four tapes or reels 41 which are connected at their lower ends to a container-engaging assembly 43.
  • the container-engaging assembly 43 comprises engaging means (which may, for example, be provided at the comers of the assembly 43, in the vicinity of the tapes 41 ) configured to engage with features of the containers 9.
  • the containers 9 may be provided with one or more apertures in their upper sides with which the engaging means can engage.
  • the engaging means may be configured to hook under the rims or lips of the containers 9, and/or to clamp or grasp the containers 9.
  • the tapes 41 may be wound up or down to raise or lower the container-engaging assembly, as required.
  • One or more motors or other means may be provided to effect or control the winding up or down of the tapes 41 .
  • the body 33 of the illustrated bot 31 has an upper portion 45 and a lower portion 47.
  • the upper portion 45 is configured to house one or more operation components (not shown).
  • the lower portion 47 is arranged beneath the upper portion 45.
  • the lower portion 47 comprises a container-receiving space or cavity for accommodating at least part of a container 9 that has been raised by the container-lifting means 39.
  • the container-receiving space is sized such that enough of a container 9 can fit inside the cavity to enable the bot 31 to move across the track structure 13 on top of storage structure 1 without the underside of the container 9 catching on the track structure 13 or another part of the storage structure 1 .
  • the container-lifting means 39 controls the tapes 41 to lower the container-gripping assembly 43 and the corresponding container 9 out of the cavity in the lower portion 47 and into the intended position.
  • the intended position may be a stack 11 of containers 9 or an egress point of the storage structure 1 (or an ingress point of the storage structure 1 if the bot 31 has moved to collect a container 9 for storage in the storage structure 1 ).
  • the upper and lower portions 45, 47 are separated by a physical divider, in other embodiments, the upper and lower portions 45, 47 may not be physically divided by a specific component or part of the body 33 of the bot 31 .
  • the bot 31 includes a wheel-positioning mechanism for selectively engaging either the first set of wheels 35 with the first set of tracks 17 or the second set of wheels 37 with the second set of tracks 19.
  • the wheel-positioning mechanism is configured to raise and lower the first set of wheels 35 and/or the second set of wheels 37 relative to the body 33, thereby enabling the load-handling device 31 to selectively move in either the first direction or the second direction across the tracks 17, 19 of the storage structure 1 .
  • the wheel-positioning mechanism may include one or more linear actuators, rotary components or other means for raising and lowering at least one set of wheels 35, 37 relative to the body 33 of the bot 31 to bring the at least one set of wheels 35, 37 out of and into contact with the tracks 17, 19.
  • only one set of wheels is configured to be raised and lowered, and the act of lowering the one set of wheels may effectively lift the other set of wheels clear of the corresponding tracks while the act of raising the one set of wheels may effectively lower the other set of wheels into contact with the corresponding tracks.
  • both sets of wheels may be raised and lowered, advantageously meaning that the body 33 of the bot 31 stays substantially at the same height and therefore the weight of the body 33 and the components mounted thereon does not need to be lifted and lowered by the wheelpositioning mechanism.
  • the bot 31 is moved as necessary in the X and Y directions so that the container-gripping assembly 43 is positioned above the stack 11.
  • the container-gripping assembly 43 is then lowered vertically in the Z direction to engage with the bin 10 on the top of the stack 11 , as shown in Figure 3(c).
  • the container-gripping assembly 43 grips the bin 10, and is then pulled upwards on the cables 38, with the bin 10 attached.
  • the bin 10 is accommodated within the vehicle body 32 and is held above the level of the rails 22.
  • the load handling device 30 can be moved to a different position in the X- Y plane, carrying the bin 10 along with it, to transport the bin 10 to another location.
  • the cables 38 are long enough to allow the load handling device 30 to retrieve and place bins from any level of a stack 11 , including the floor level.
  • the weight of the vehicle 32 may be comprised in part of batteries that are used to power the drive mechanism for the wheels 35, 37.
  • a plurality of identical load handling devices 31 are provided, so that each bot 31 can operate simultaneously to increase the throughput of the system.
  • the system illustrated in Figure 4 may include specific locations, known as ports, at which bins 10 can be transferred into or out of the system.
  • An additional conveyor system (not shown) is associated with each port, so that bins 10 transported to a port by a bot 31 can be transferred to another location by the conveyor system, for example to a picking station (not shown).
  • bins 10 can be moved by the conveyor system to a port from an external location, for example to a bin-filling station (not shown), and transported to a stack 11 by the bots 31 to replenish the stock in the system.
  • Each bot 31 can lift and move one bin 10 at a time. If it is necessary to retrieve a bin 10b (“target bin”) that is not located on the top of a stack 11 , then the overlying bins 10a (“non-target bins”) must first be moved to allow access to the target bin 10b. This is achieved in an operation referred to hereafter as “digging”.
  • one of the bots 31 sequentially lifts each non-target bin 10a from the stack 11 containing the target bin 10b and places it in a vacant position within another stack 11 .
  • the target bin 10b can then be accessed by the bot 31 and moved to a port for further transportation.
  • Each of the bots 31 is under the control of a grid controller.
  • Each individual bin 10 in the system is tracked, so that the appropriate bins 10 can be retrieved, transported and replaced as necessary. For example, during a digging operation, the locations of each of the non-target bins 10a is logged, so that the non-target bins 10a can be tracked.
  • the system described with reference to Figures 1 to 4 has many advantages and is suitable for a wide range of storage and retrieval operations.
  • it allows very dense storage of product, and it provides a very economical way of storing a huge range of different items in the bins 10, while allowing reasonably economical access to all of the bins 10 when required for picking.
  • FIG 6 shows a schematic depiction of an automated storage and retrieval system 100 which comprises first grid structure 50A and second grid structure 50B upon which a plurality of bots (not shown in Figure 6) may operate.
  • first and second grid structures is as described above with reference to Figures 1 -5 and allows products to be decanted into a container, containers to be stored within a stack within a grid structure and the containers retrieved such that one or more of the objects may be picked from the container and then packed into a customer order.
  • Each of the grid structures comprises a respective plurality of safety elements 82A 82B.
  • the safety elements may comprise, for example, a switch located by the perimeter of a grid structure, an interlock on a door or gate which allows access onto the grid surface, an override switch located elsewhere within or near to the automated storage and retrieval system, etc.
  • Each of the respective plurality of safety elements 82A 82B is connected to a respective safety PLC 80A 80B and each safety PLC is connected to a respective safety transmitter 90A 90B.
  • Each of the safety transmitters 90A 90B are connected to a data switch 300, for example via an Ethernet circuit carried over a single mode optical fibre.
  • first and second grid structures may be located in different environmental conditions, for example the first grid structure may hold items under ambient conditions whereas the second grid structure may hold items which require refrigeration (for example a temperature of 2-5°C). Alternatively, the first and second grid structures may be located in the same environmental conditions but the grid structures are physically separate for other reasons. It should also be understood that the following disclosure is equally applicable to an automated storage and retrieval system which comprises only a single grid structure or more than two grid structures.
  • the automated storage and retrieval system 100 also comprises a grid controller 200 which is configured to, inter alia, control the operation of the bots which are operating on the grid structures.
  • the automated storage and retrieval system 100 further comprises an OPC server 220, a DHCP server 230, and an NTP server 240, all of which are connected to the grid controller 200.
  • the grid controller 200 is also connected to the safety PLC 80A 80B and the safety transmitter 90A 90B for both of the grid structures 50 (connections shown in dashed lines in Figure 6).
  • the automated storage and retrieval system 100 further comprises a primary base station 60 and a secondary base station 70.
  • the base stations are arranged such that they can transmit signals to and receive signals from both the first grid structure 50A and the second grid structure 50B.
  • the primary base station and the secondary base station each have a respective connection to the data switch 300, for example an Ethernet connection which is transmitted over a single mode optical fibre.
  • the grid controller also controls the operations of the other components of the grid structures such that products may be decanted into containers, containers stored within a stack within a grid structure, containers retrieved for picking, products picked from a container for packing, packed orders loaded to delivery vehicles, etc.
  • FIG. 7 shows a schematic depiction of the grid controller 200 which comprises a robot control system 202, a maintenance/monitoring system 204, base station controller 206, one or more warehouse management systems (WMS) 212, one or more order management systems 214 and one or more information management systems 216, respectively operably coupled to the robot control system 202.
  • the warehouse management systems 212 stores information, for example, items required for an order, SKUs in the warehouse, expected/predicted orders, items missing on orders, when an order is to be loaded on a transporter, expiry dates on items, what items are in which container, and/or whether items are fragile or big and bulky, etc.
  • the bot control system 202 is configured, in this example, to control the navigation/routing of bots, including, but not limited to, moving from one location to another, collision avoidance, optimisation of movement paths, and/or control of activities to be performed.
  • the bot control system 202 may be implemented, in this example, using one or more servers, each containing one or more processors configured based upon instructions stored upon one or more non-transitory computer- readable storage media.
  • the bot control system 202 is configured to send control messages to one or more bots, receive one or more updates from one or more bots, and communicate with one or more bots using a real or near-real time protocol.
  • the bot control system 202 receives information indicating bot location and availability from base stations 60 and 70.
  • the bot control system 202 is configured to keep track of the number of bots available, the status of one or more bots, the location of one or more bots and/or their current instruction sets.
  • the bot control system 202 may be configured, in this example, to process and/or send control messages to the one or more bots in anticipation of future movements, potentially reducing the processor load, and also proactively managing the traffic load with respect to the communications links.
  • Such an implementation could be advantageous in light of complex algorithms in use by the bot control system 202 in determining optimal pathways, calculating optimal locations for containers and/or determining reservations and/or clearances.
  • the maintenance/monitoring system (MMS) 204 is configured, in this example, to provide monitoring functions, including receiving alerts from one or more bots via a base station 60 70, establishing connections to query bots, etc.
  • the MMS 204 also comprises an interface (not shown) for the configuration of monitoring functions.
  • the MMS 204 interacts with the bot control system 202 to indicate when certain bots should be recalled.
  • the base station controller 206 stores master routing information to map bots, base stations, and grids. In some examples, one base station controller 206 is provided per warehouse, but in other examples, a plurality of base station controllers can be employed.
  • the base station controller 206 is designed to provide high availability.
  • the base station controller 206 is configured to manage dynamic frequency selection and frequency allocation of the one or more base stations 60 70.
  • the base stations 60 and 70 are, in this example and as shown in Figure 6, organised as a pool of base stations, which can then be configured to be active, on standby or to monitor the system. Messages can be routed through a variety of communications apparatus to and from bots.
  • the communications apparatus can be any suitable communications apparatus.
  • the communications apparatus can support a Radio Frequency (RF) link, such as those falling under the 802.11 family of wireless standards.
  • the base stations 60 and 70 comprise, in this example, processing units 62, 72, digital signal processors 64, 74, and radio interfaces 66, 76.
  • each of the storage grids 50A 50B may be provided with a respective primary and secondary base stations. If a particular storage grid is so large that it cannot be covered by a single base station then multiple base stations may be provided. It should be understood that a base station controller will co-ordinate the operations of the base stations such that a bot can be handed over from a first base station to a second base station. Details of how signals may be transmitted to between a base station and a bot are disclosed in WO2015/185726, the contents of which are hereby incorporated by reference. The signals may be transmitted in an unlicensed frequency band, for example to take use of the unlicensed spectrum found around 5 GHz in Europe, Canada and the USA (specifically 5470 MHz - 5725 MHz).
  • Figure 8 shows a schematic depiction of a part of the automated storage and retrieval system 100 of Figure 6.
  • Figure 8 shows the operation of a plurality of bots 31 on the surface of a grid structure 50. For the sake of clarity, the stacks and the other components of the structure which are received beneath the grid are not shown in Figure 8.
  • Figure 8 shows that the grid structure 50 comprises a fence or barrier 52, which prevents human operatives within the facility which houses the automated storage and retrieval system from inadvertently entering onto the grid and also serves to prevent a bot from derailing and falling off the grid.
  • entrances for example doors or gates, may be provided within the fence 52.
  • Such entrances will be provided with interlocks which comprise one of the safety elements 82 such that if an entrance is opened then the bots will be brought to a stop (see below) such that a human operative that enters the grid will not be at risk of injury from collision with a bot.
  • planned maintenance events will take place when the grid is not active and the plurality of bots are not in motion.
  • control signals for the plurality of bots operating on the grid structures are generated within the grid controller 200 and transmitted to the data switch.
  • safety signals will be generated in accordance with the inputs received from each of the plurality of safety elements.
  • the safety signals will be transmitted by the respective safety transmitters 90A 90B to the data switch 300 such that a signal which comprises both bot control information and safety information is transmitted to the primary base station and the secondary base station.
  • the primary base station will then transmit the combined signal 65 to the plurality of bots 31 which are operating on the grid structures.
  • the combined signal 65 is received by each of the plurality of bots and is then processed accordingly.
  • the control signals will give each bot operational instructions, for example, instructing a bot to: determine a route to a specified grid location; follow a particular route across the grid; retrieve a container from a grid location; store a container held within the bot at a grid location; to take a specific route to the re-charging station; etc.
  • WO201 7/186825 discloses a system and a method for co-ordinating multiple bots on a grid-based automated storage and retrieval system.
  • the safety signals may cause one, some or all of a plurality of bots to cease operations, for example if one of the safety elements has generated a signal (for example, in the case that it has been detected that one of the entrances to the grid has been opened, if it has been detected that an emergency button has been pressed, etc.).
  • the safety signals may be transmitted on a periodic basis and if a safety signal is not received within a pre-determined period of time then this may cause the plurality of bots to cease operations as it can be inferred that there is an issue with the safety system.
  • the grid controller 200 is connected to an NTP server 240.
  • Each of the safety transmitters 90 and the base stations 60 70 are connected to the NTP server via the grid controller such that the safety transmitter 60A, the primary base station 60A and the secondary base station 70A for the first grid structure 50A are synchronised with the grid controller.
  • the safety transmitter 60B, the primary base station 60B and the secondary base station 70B for the second grid structure 50B are synchronised with the grid controller. This synchronisation enables the combine signal 65 which comprises both control signals and the safety signals to be transmitted.
  • Figure 9 shows a schematic depiction of a bot in relation to the reception and processing of the combined signal 65 transmitted by the base station 60.
  • the bot 31 further comprises an antenna 32 which is located on the exterior of the bot body 33 and is configured to receive the combined signal 65 transmitted by the base station.
  • the bot further comprises a bot communication module 34, a safety receiver 36, a real time controller 38 and a bot PC 40.
  • the antenna 32 is connected to a bot communication module 34 which separates the control signals generated by the grid controller from the safety signals generated by the safety transmitter.
  • the control signals are then sent to the bot PC 40.
  • the bot PC 40 is in communication with the first and second sets of wheels 35, 37 and can send signals to activate the first or second sets of wheels as appropriate.
  • the bot PC 40 is also in communication with the container-lifting means 39 (see Figures 4 & 5) and can control the container-lifting means to, for example, lift a container from a stack within the grid structure into the bot, to lower a container from within the bot into a stack within the grid, etc..
  • the bot PC is able to interpret and execute the control signals such that the bot can be operated in an efficient manner as a part of the plurality of bots.
  • the safety signals which are separated from the combined signal by the bot communication module 34 are sent to the safety receiver 36, the safety receiver being configured to process the safety signals. If a safety condition is detected by the safety receiver then the safety receiver may cause the real time controller 38 to send a safety control signal to the bot PC 40.
  • the reception of the safety control signal from the real time controller overrides the control signals received by the bot PC from the grid controller such that the operations of the bot are stopped. If the bot is in the process of moving from a first grid location to a second grid location then the bot will be stopped at its current location. A stationary bot which is in the process of lifting or lowering a container may complete that action but will not take any further action until the safety control signal is cancelled.
  • Figure 10a shows a schematic depiction of a safety signal 905 which comprises five fields.
  • the first field 915 comprises a Grid ID
  • the second field 925 comprises a grid state
  • the third field 935 comprises a sequence number
  • the fourth field 945 comprises a timestamp
  • the fifth field 955 comprises a cyclic redundancy code (CRC).
  • the grid controller will assign a Grid ID to each of the plurality of bots and the respective Grid ID will be transmitted to each bot using a control signal.
  • a bot will not act on a safety message which does not comprise the Grid ID which has been assigned to that bot.
  • the Grid State field comprises a Grid State, which may be one of Grid Stop, Grid Hold or Grid Reset.
  • the Grid State is received by the bot and determines the operation of the bot (see below).
  • the Sequence field 935 comprises a unique numerical identifier which is incremented sequentially as each safety signal is transmitted. This enables the safety receiver to determine if a safety signal is received in its correct sequence or not.
  • the timestamp field 945 comprises a timestamp which is generated by the safety transmitter 90.
  • the CRC field 955 comprises a cyclic redundancy code (CRC) which can be analysed to confirm that the safety signal has been transmitted and received without the signal being corrupted or interfered with.
  • CRC cyclic redundancy code
  • FIG. 10b shows a schematic depiction of the process by which a packet received at a bot can be processed by the bot PC.
  • the process begins at step S900 when a packet is received and at step S910 the Grid ID stored in field 915 of the packet is compared with the Grid ID that is held by the bot. If the Grid IDs match then the process proceeds to step S920: if the Grid IDs do not match then the packet is discarded at step S960 and the process terminates at step S970.
  • a CRC check is undertaken and if the CRC in field 955 does not pass then the packet is discarded at step S960.
  • step S930 the time is compared with the value stored in the timestamp field 945 and if the packet has not been received within a predetermined time period then it will be discarded (S960). Otherwise, the packet is passed to step S940 where the sequence number can be assessed to determine that the packet has been received in sequence (or has been received no more than a predetermined number of packets from its position in the sequence). If the packet has been received in sequence then it will be passed to step S950, at which the grid state data can be applied to the bot. If the packet is determined to be received out of sequence then the packet is discarded at step S960 and the process terminates at step S970.
  • Figure 11 shows a first example of the structure of the frames that are used in the communications system 100.
  • Figure 11 shows a plurality of frames 702, each frame comprising a downlink subframe (DL) and an uplink subframe (UL).
  • Figure 11 shows five frames F1 to F5 (shown using reference numerals 702A - 702E respectively).
  • the downlink subframe and the uplink subframe each occupy a 10 ms time slot and thus a single frame occupies a 20 ms time slot.
  • these five frames comprise a multiframe and thus each multiframe occupies a time slot of 100 ms.
  • each of the frames (and thus the multiframe) occupies 10 MHz of bandwidth.
  • the communications system transmits a series of multiframes, each of which may comprise 5 frames, as discussed above.
  • FIG 12 shows a schematic depiction of the structure of a downlink subframe that is used in the communications system 100.
  • Each downlink subframe is divided into a plurality of tiles, such that one or more of the tiles can be used to support a communication link between the central computer and a bot.
  • the downlink subframe is divided into 800 tiles, with 40 subdivisions in the frequency domain (that is, the graphical representation shown in Figure 12 has 40 columns) and 20 subdivisions in the time domain (that is, the graphical representation in Figure 12 has 20 rows).
  • the effective bandwidth of the subframe is 9 MHz and thus each tile corresponds to 225 kHz.
  • the subframe occupies a time slot of 10 ms and thus each tile corresponds to 0.5 ms.
  • the first two columns of tiles that is the tiles in the first two time slots of the downlink, are reserved for use for broadcasting messages to the bots and for detecting intrusion by radio signals from other sources.
  • a plurality of tiles 1210 which comprise a portion of the first column of tiles are reserved for transmitting the safety signal.
  • the safety signals are transmitted as a ‘black channel’ and thus are separated from the control signals that are transmitted to the bots, using either a thin pipe or a fat pipe.
  • a low capacity communications link may comprise two tiles and is used to transmit a command to a particular bot, for example to inform the bot of a grid location to move to, to instruct the bot to retrieve a container or to deposit a container.
  • the bot will confirm receipt and processing of the command by transmitting a message to the central computer using a low capacity communications link in the following uplink subframe. For example, if a message is received in subframe DL3 then it will be acknowledged in subframe UL3. If this is not possible then the bot will wait and respond in subframe UL3 in the subsequent multiframe.
  • Such a low capacity communications link may be referred to as a thin Pipe-
  • a bot When a bot is inducted into the storage system it may be assigned two tiles in a downlink subframe which are exclusively reserved for use by that bot.
  • the tiles may be represented by a unique thin pipe number which can be mapped to the two tiles which are associated with the link.
  • the bot will be assigned two tiles in the subsequent uplink subframe which comprise a thin pipe for the bot to use when communicating with the base station.
  • the thin pipe numbers for both the downlink and the uplink thin pipe numbers may be stored in the bot for use in controlling subsequent communications.
  • tiles 1212 are reserved for use to support thin pipes. These thin pipe tiles 1212 comprise 10 columns of the subframe, that is 400 tiles.
  • each multiframe comprises 5 frames (each frame comprising a downlink subframe and an uplink subframe) and thus it can be seen that such a system is able to support up to 1000 bots.
  • a high capacity communications link may be established between the central computer and a bot.
  • a high capacity communications link which may be referred to as a fat pipe, requires 160 tiles and preferably comprises four contiguous rows of tiles in the time domain (that is, the tiles of four consecutive time slots).
  • a fat pipe may be used to recover data from a bot (for example log files, system configurations, etc.), to transmit data to a bot (updating system software etc.) or to enable a bot to be remotely piloted in the event that the bot is not able to direct itself on the grid.
  • the downlink subframe is capable of supporting two fat pipes using a first plurality of tiles 1214 and a second plurality of tiles 1216.
  • FIG 13 shows a schematic depiction of the structure of an uplink subframe that is used in the communications system 100.
  • each uplink subframe is divided into 800 tiles, with 40 subdivisions in the frequency domain and 20 subdivisions in the time domain.
  • the effective bandwidth of the subframe is 9 MHz and thus each tile corresponds to 225 kHz.
  • the subframe occupies a time slot of 10 ms and thus each tile corresponds to 0.5 ms.
  • the second column of tiles is reserved for detecting intrusion by radio signals from other sources.
  • the remaining tiles are reserved for use by thin pipes and fat pipes, as required.
  • the subframe comprises 400 tiles 1312 for supporting thin pipes and first 1314 and second 1316 pluralities of tiles which can each support a fat pipe. If required, tiles which are assigned for use for a fat pipe may be reassigned such that they may support a plurality of thin pipes, or vice versa.
  • Figures 14 and 15 show a schematic depiction of an aspect of a communications system which shows the process by which signals are transmitted from a safety transmitter to a bot, via a base station.
  • Figure 14 shows a schematic depiction of simplified view of a part of the communications system described above with reference to Figure 6 and shows the first safety transmitter 90A, first base station 60 and the NTP server 240.
  • the NTP (Network Time Protocol) server provides a reference time signal which enables the various network elements and components to operate in a synchronised manner.
  • a safety signal generated by the first safety transmitter is transmitted via the first base station 60 as a part of a composite signal.
  • the composite signal is transmitted to the bots 31 on the first grid 50A.
  • Each of the bots 31 which receive the signal (for the sake of clarity, Figure 14 shows only a single bot but it can be assumed that the grid will have many bots, possibly hundreds of bots for a large installation, active on the grid at any one time) will extract the safety signal from the composite signal using the bot communication module (BCM) 34 such that the safety signal is routed to the safety receiver 36. The safety receiver will then process the safety signal.
  • BCM bot communication module
  • FIG 15 shows a graphical depiction of the method by which safety signals are transmitted and processed
  • a first timestamp is generated and written into the safety signal (S1500).
  • the safety signal is then transmitted to the first base station via the data switch 300 and the safety signal is then inserted into the composite signal along with the control signals generated by the grid controller.
  • the base station generates a second timestamp (S1510) which can be written into the composite signal and then transmitted to the bots operating on the first grid (S1520).
  • the BCM of each bot which receives the composite signal will process the composite signal to extract the safety signal (S1530).
  • the BCM will also append the second timestamp from the composite signal such that the safety receiver receives both the safety signal and the second timestamp.
  • the safety receiver may then examine the first and second time stamps (S1540). For example, both the first and the second timestamps should be received by the bot within a predetermined time window. If the delay between the first and the second timestamps is too great then the safety signal will be discarded.
  • the predetermined time window is selected from within the range of 5-20 ms.
  • each of the grid structures 50 may be operated in two different modes.
  • a grid structure When a grid structure is operating in a Grid Active mode then the grid is operating in accordance with the control signals sent from the grid controller to the bots, via the base stations.
  • the Grid Active mode the potential safety hazards within the grid are contained, for example by the barrier surrounding the grid structure.
  • the Grid Stopped mode is entered, in response to a signal sent from a safety transmitter.
  • the safety event may be a gate onto the grid surface being entered, an alarm being activated, an E-stop controller being activated, etc. It should be understood that it is possible for one of the grids to be in the Grid Active mode whilst the other is in the Grid Stopped mode. It may be necessary for operational reasons for an active grid to be shut down if the other grid is in Grid Stopped for an extended period of time as it will not be possible to fulfil orders using items held in the inactive grid.
  • a grid enters the Grid Stopped mode then it should not be possible to reactivate the grid without human intervention. For example, powering on the grid system, or a component of the grid system, should not lead to the system (or component) to restart. This enables a grid to be restarted once it has been determined that all personnel have vacated the grid and would not be exposed to danger by a system restart.
  • the automated storage and retrieval system may comprise a plurality of independent grids.
  • Each of the grids may be assigned a unique grid ID value.
  • the grid ID value is used by the associated safety transmitter such that a safety transmitter is able to address all of the safety receivers that are active on the associated grid.
  • a grid ID can be assigned to a safety receiver of a bot, for example, when the bot is inducted onto the grid.
  • the activation of a safety device such as a wired emergency stop device, will cause the safety transmitter to which the safety device is connected to transmit a Grid Stop signal which will be acted on by the safety receivers of the bots active on that grid. Bots active on other grids will continue to operative in the Grid Active mode.
  • redundant links may be provided between: each safety PLC and the grid controller; between each safety transmitter and the grid controller; between each safety transmitter and the data switch; between the data transmitter and each primary base station; and between the data transmitter and each secondary base station.
  • each safety PLC and the grid controller between each safety transmitter and the grid controller; between each safety transmitter and the data switch; between the data transmitter and each primary base station; and between the data transmitter and each secondary base station.
  • the data switch may comprise a first switch and a second switch, which may both have redundant links to the safety transmitter, primary base stations, secondary base stations etc.
  • both the first and second switches may be operational at all times.
  • the first switch may be designated as a main switch which is operational with the second switch designated as a standby switch. In the event that a problem is detected with the main switch, or a connection to or from the main switch, then the standby switch may be activated such that it becomes operational.
  • the grid controller may be connected to the first and second switches via first and second routers such that there are redundant links between the grid controller and the first and second switches.
  • Figure 16 shows a schematic depiction of a computer device 1600 used in the implementation of a communications system of the present disclosure that may include a central processing unit (“CPU”) 1602 connected to a storage unit 1614 and to a random access memory 1606.
  • the CPU 1602 may process an operating system 1601 , application program 1603, and data 1623.
  • the operating system 1601 , application program 1603, and data 1623 may be stored in storage unit 1614 and loaded into memory 1606, as may be required.
  • Computer device 1600 may further include a graphics processing unit (GPU) 1622 which is operatively connected to CPU 1602 and to memory 1606 to offload intensive image processing calculations from CPU 1602 and run these calculations in parallel with CPU 1602.
  • GPU graphics processing unit
  • An operator 1607 may interact with the computer device 1600 using a video display 1608 connected by a video interface 1605, and various input/output devices such as a keyboard 1615, mouse 1612, and disk drive or solid state drive 1614 connected by an I/O interface 1604.
  • the mouse 1612 may be configured to control movement of a cursor in the video display 1608, and to operate various graphical user interface (GUI) controls appearing in the video display 1608 with a mouse button.
  • GUI graphical user interface
  • the disk drive or solid state drive 1614 may be configured to accept computer readable media 1616.
  • the computer device 1600 may form part of a network via a network interface 1611 , allowing the computer device 1600 to communicate with other suitably configured data processing systems (not shown).
  • One or more different types of sensors 1635 may be used to receive input from various sources.
  • control of the storage system may be performed by an appropriately configured industrial computing device, however the disclosure may be implemented using virtually any manner of computer device including a desktop computer, laptop computer, tablet computer, wireless handheld or a cloud computing platform.
  • the computing device or devices may execute one or more software instances, for example virtual machines and or containers.
  • the present system and method may also be implemented as a computer-readable/useable medium that includes computer program code to enable one or more computer devices to implement each of the various process steps in a method in accordance with the present disclosure. In case of more than one computer devices performing the entire operation, the computer devices are networked to distribute the various steps of the operation.
  • the terms computer-readable medium or computer useable medium comprises one or more of any type of physical embodiment of the program code.
  • the computer-readable/useable medium can comprise program code embodied on one or more portable storage articles of manufacture (e.g. an optical disc, a magnetic disk, a tape, etc.), on one or more data storage portioned of a computing device, such as memory associated with a computer and/or a storage system.
  • the disclosure provides systems, devices, methods, and computer programming products, including non-transient machine-readable instruction sets, for use in implementing such methods and enabling the functionality described previously.
  • n is one of x, y and z
  • movement in the n-direction is intended to mean movement substantially along or parallel to the n-axis, in either direction (i.e. towards the positive end of the n-axis or towards the negative end of the n-axis).
  • connect and its derivatives are intended to include the possibilities of direct and indirection connection.
  • x is connected to y
  • y is intended to include the possibility that x is directly connected to y, with no intervening components, and the possibility that x is indirectly connected to y, with one or more intervening components.
  • the words “directly connected”, “direct connection” or similar will be used.
  • the word “support” and its derivatives are intended to include the possibilities of direct and indirect contact.
  • x supports y is intended to include the possibility that x directly supports and directly contacts y, with no intervening components, and the possibility that x indirectly supports y, with one or more intervening components contacting x and/or y.
  • mount and its derivatives are intended to include the possibility of direct and indirect mounting.
  • x is mounted on is intended to include the possibility that x is directly mounted on y, with no intervening components, and the possibility that x is indirectly mounted on y, with one or more intervening components.
  • the word “comprise” and its derivatives are intended to have an inclusive rather than an exclusive meaning.
  • x comprises is intended to include the possibilities that x includes one and only one y, multiple y’s, or one or more j/s and one or more other elements. Where an exclusive meaning is intended, the language “x is composed of will be used, meaning that x includes only y and nothing else.
  • controller is intended to include any hardware which is suitable for controlling (e.g. providing instructions to) one or more other components.
  • a processor equipped with one or more memories and appropriate software to process data relating to a component or components and send appropriate instructions to the component(s) to enable the component(s) to perform its/their intended function(s).
  • the present disclosure provides a communications system for use with a plurality of load handling devices in an automated storage and retrieval system.
  • the communications system may transmit a signal which integrates commands to be communicated to and from the plurality of load handling devices as well as safety signals, which can cause the operation of the storage and retrieval system to be ceased if particular conditions are met, for example an intrusion into the operational area of the storage and retrieval system.

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Abstract

L'invention concene un système de communication destiné à être utilisé avec une pluralité de dispositifs de gestion de charge dans un système de stockage et de récupération automatisé. Le système de communication peut transmettre un signal qui intègre des commandes à communiquer vers et à partir de la pluralité de dispositifs de gestion de charge ainsi que des signaux de sécurité, ce qui peut amener l'arrêt du fonctionnement du système de stockage et de récupération si des conditions particulières sont satisfaites, par exemple une intrusion dans la zone opérationnelle du système de stockage et de récupération.
PCT/EP2023/055919 2022-03-08 2023-03-08 Système de commande WO2023170167A1 (fr)

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Citations (5)

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WO2015185726A2 (fr) 2014-06-05 2015-12-10 Ocado Innovation Limited Systèmes et procédés de communication
WO2017186825A1 (fr) 2016-04-26 2017-11-02 Ocado Innovation Limited Système de coordination de manipulateur de charge robotique, système de grille cellulaire et procédé de coordination d'un manipulateur de charge robotique
WO2018141876A1 (fr) * 2017-02-01 2018-08-09 Ocado Innovation Limited Système de sécurité de système de stockage et de préparation automatisé et son procédé de fonctionnement
WO2018177788A1 (fr) 2017-03-27 2018-10-04 Ocado Innovation Limited Système de communication sans fil avec discrimination entre signaux reçus externes
WO2021028709A1 (fr) * 2019-08-09 2021-02-18 Nokia Technologies Oy Appareil et procédé pour fournir un commutateur d'arrêt d'urgence pour un robot commandé en réseau

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JP7319309B2 (ja) * 2018-06-12 2023-08-01 アウトストア・テクノロジー・エーエス レールシステム上にある不具合のある車両を取り扱うための方法、および当該方法を利用する倉庫システム

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Publication number Priority date Publication date Assignee Title
WO2015185726A2 (fr) 2014-06-05 2015-12-10 Ocado Innovation Limited Systèmes et procédés de communication
EP3152956A2 (fr) * 2014-06-05 2017-04-12 Ocado Innovation Limited Systèmes et procédés de communication
WO2017186825A1 (fr) 2016-04-26 2017-11-02 Ocado Innovation Limited Système de coordination de manipulateur de charge robotique, système de grille cellulaire et procédé de coordination d'un manipulateur de charge robotique
WO2018141876A1 (fr) * 2017-02-01 2018-08-09 Ocado Innovation Limited Système de sécurité de système de stockage et de préparation automatisé et son procédé de fonctionnement
WO2018177788A1 (fr) 2017-03-27 2018-10-04 Ocado Innovation Limited Système de communication sans fil avec discrimination entre signaux reçus externes
WO2021028709A1 (fr) * 2019-08-09 2021-02-18 Nokia Technologies Oy Appareil et procédé pour fournir un commutateur d'arrêt d'urgence pour un robot commandé en réseau

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