DESC:MULTI-LEVEL VEHICLE FOR AUTOMATION IN MATERIAL HANDLING

FIELD OF THE PRESENT DISCLOSURE
[0001] The present invention relates generally to automated storage and retrieval systems (AS/RS) for warehouse operations. More specifically, the invention pertains to a multi-level vehicle designed to enhance the efficiency of storage and retrieval operations across multiple levels of storage racks within a warehouse.

BACKGROUND
[0002] Warehouses or distribution centres are facilities being used to collect, store, and dispatch inventory to fulfil various orders. A typical warehouse/distribution/order fulfilment centre may store a large number of different varieties of goods/items in a multi-level rack system with each rack having multiple shelves arranged at different storage levels. Such items may be stored at each of these shelves in storage containers such as trays, totes, pallets, or cartons etc. Traditionally, these items were being stored and retrieved from the storage racks by human operators. However, with increasing order volumes and limited warehouse space, a greater number of racks were installed vertically to store the items, and manual storage and retrieval of the storage containers from such multi-level racks became overly challenging. While this could be managed by deploying a large workforce for material handling operations, countries around the world are today faced with increased labour shortages. At the same time, manual handling of items in warehouses results in slower, inefficient, and inaccurate operations. To overcome these problems, a number of material handling equipment such as automated forklifts, shuttles/carts, conveyors, and mobile robots were devised to automate warehouse operations.
[0003] Selection of a suitable material handling system for storage, retrieval, and picking operations can be dependent on various parameters such as nature of items, storage structure, volume of items, throughput requirements (number of inventory/items fulfilled or processed in a given unit of time), cost involved in manufacturing and installation of the system, etc. These parameters need to be factored in while opting for a suitable material handling system which delivers the desired results without being cost prohibitive.
[0004] The existing material handling systems for storage, retrieval, and picking of cartons, totes, trays, bins, baskets etc. in a fixed infrastructure disclose carton shuttles and mini-load ASRS. However, application of both the systems have the following limitations. A system comprising carton shuttles necessarily requires a huge infrastructure wherein each level of a storage rack in a multi-level rack system is required to have an aisle supplemented by a track and at least one shuttle configured to run on the track along the aisle to store and retrieve the items. This system is effective in scenarios where the warehouse operations require extremely high throughput suitable for inventory with a high turnover/demand. However, the tremendous cost involved in manufacturing, installation, and maintenance of the system makes it less feasible for the warehouses requiring relatively lower throughput. On the other hand, while Mini-Load Automated Storage and Retrieval Systems (ASRS) do not require installation of tracks at each level, yet its bulky nature makes it difficult to install and also requires a larger floor space in the warehouse to move between the storage racks. Moreover, it delivers a much lower throughput which may be suitable for inventory with low turnover/demand. Clearly, none of the above discussed existing systems can be opted to address inventory with a medium turnover/demand which at the same time remains cost efficient compared to the existing systems.
[0005] Therefore, in light of the foregoing discussion, there exists a need for a system that can cater to medium throughput requirements, providing a balance between cost and operational efficiency.

SUMMARY
[0006] In an aspect, a multi-level vehicle for use in a multi-level warehouse racking system is provided. The multi-level vehicle comprises a base carriage assembly configured for horizontal movement along an X-axis of the multi-level warehouse racking system. The multi-level vehicle further comprises a vertical column assembly affixed to the base carriage assembly. The vertical column assembly comprises one or more guiding columns extending along a Z-axis. The multi-level vehicle further comprises a lifting assembly configured for vertical movement along the one or more guiding columns of the vertical column assembly. The load handling mechanism in the lifting assembly is further configured for storage and retrieval operation.
[0007] In one or more embodiments, the base carriage assembly comprises a base frame, a plurality of drive wheels, and a drive mechanism operatively coupled to at least one of the plurality of drive wheels, for enabling the horizontal movement of the multi-level vehicle along the X-axis.
[0008] In one or more embodiments, the drive mechanism comprises at least one drive motor, at least one drive gearbox, and at least one drive shaft, wherein the drive shaft is coupled to the at least one drive motor via the at least one drive gearbox to drive the at least one of the plurality of drive wheels.
[0009] In one or more embodiments, the vertical column assembly comprises one or more guiding columns and a belt and pulley mechanism for controlling the vertical movement of the lifting assembly.
[0010] In one or more embodiments, the lifting assembly comprises a lifting carriage, and a load handling mechanism supported on the lifting carriage. The load handling mechanism is configured to travel, or extend and retract along a Y-axis for storing and retrieving a storage bin.
[0011] In one or more embodiments, the load handling mechanism is adapted as a telescopic gripper.
[0012] In one or more embodiments, the load handling mechanism is adapted to be detachable from the lifting carriage.
[0013] In another aspect, a material handling system is provided. The material handling system comprises a multi-level vehicle configured to navigate within a multi-level warehouse racking system of the material handling system. The multi-level vehicle comprises a base carriage assembly configured for horizontal movement along an X-axis of the multi-level warehouse racking system. The multi-level vehicle further comprises a vertical column assembly affixed to the base carriage assembly. The vertical column assembly extends along a Z-axis. The multi-level vehicle further comprises a lifting assembly configured for vertical movement along the vertical column assembly. The load handling mechanism in the lifting assembly is further configured for storage and retrieval operation. The material handling system further comprises a controller configured to receive or issue a task instruction for storage and retrieval orders for storage bins from within the multi-level warehouse racking system, including X, Y, and Z coordinates of the storage bin. The material handling system further comprises a vehicle control unit configured to control navigation and operation of the multi-level vehicle to facilitate either retrieval or storage of the storage bin, based on the task instruction.
[0014] In one or more embodiments, the lifting assembly comprises a lifting carriage, and a load handling mechanism supported on the lifting carriage. The load handling mechanism is configured to travel, or extend and retract along a Y-axis.
[0015] In yet another aspect, a method for retrieval or storage of a storage bin in a multi-level warehouse racking system is provided. The method comprises issuing a task instruction to a multi-level vehicle, to retrieve or store the storage bin in the multi-level warehouse racking system. The method further comprises controlling a base carriage assembly of the multi-level vehicle for horizontal movement along the X-axis. The method further comprises initiating a vertical movement of a lifting assembly of the multi-level vehicle on a vertical column assembly along a Z-axis. The method further comprises operating the load handling mechanism in the lifting assembly to travel, or extend and retract along a Y-axis within the multi-level warehouse racking system.
[0016] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described earlier, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE FIGURES
[0017] For a more complete understanding of example embodiments of the present disclosure, reference is now made to the following descriptions taken in connection with the accompanying drawings in which:
[0018] FIG. 1A illustrates a perspective view of a multi-level vehicle, in accordance with one or more exemplary embodiments of the present disclosure;
[0019] FIG. 1B illustrates another perspective view of the multi-level vehicle, in accordance with one or more exemplary embodiments of the present disclosure;
[0020] FIG. 1C illustrates a planar view of the multi-level vehicle, in accordance with one or more exemplary embodiments of the present disclosure;
[0021] FIG. 2 illustrates a perspective view of a base carriage assembly of the multi-level vehicle, in accordance with one or more exemplary embodiments of the present disclosure;
[0022] FIG. 3A illustrates a perspective view of a vertical column assembly of the multi-level vehicle, in accordance with one or more exemplary embodiments of the present disclosure;
[0023] FIG. 3B illustrates a planar view of the vertical column assembly, in accordance with one or more exemplary embodiments of the present disclosure;
[0024] FIG. 4A illustrates a perspective view of a lifting assembly of the multi-level vehicle, in accordance with one or more exemplary embodiments of the present disclosure;
[0025] FIG. 4B illustrates another perspective view of the lifting assembly, in accordance with one or more exemplary embodiments of the present disclosure;
[0026] FIG. 4C illustrates yet another perspective view of the lifting assembly, in accordance with one or more exemplary embodiments of the present disclosure;
[0027] FIG. 4D illustrates a planar view of the lifting assembly, in accordance with one or more exemplary embodiments of the present disclosure;
[0028] FIG. 5 illustrates a block diagram of a material handling system utilizing the multi-level vehicle, in accordance with one or more exemplary embodiments of the present disclosure; and
[0029] FIG. 6 illustrates a flowchart of a method of operation of the material handling system utilizing the multi-level vehicle, in accordance with one or more exemplary embodiments of the present disclosure.

DETAILED DESCRIPTION
[0030] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one skilled in the art that the present disclosure is not limited to these specific details.
[0031] Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not for other embodiments.
[0032] Furthermore, in the following detailed description of the present disclosure, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be understood that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the present disclosure.
[0033] The present disclosure provides a material handling system (hereinafter, sometimes, referred to as “system” without any limitations) for efficient storage, retrieval, and picking operations in warehouses with multilevel rack infrastructure. The present material handling system utilizes a multi-level vehicle designed to increase the efficiency of Automated Storage and Retrieval Systems (hereinafter, sometimes, referred to as “AS/RS” or simply “ASRS” without any limitations) within the warehouses. The multi-level vehicle is an autonomous or semi-autonomous vehicle that can access multiple storage levels within a warehouse racking system. The multi-level vehicle can navigate in horizontal and vertical directions to store, retrieve and pick cartons, totes, baskets, trays, crates, bins etc., addressing a significant operational challenge in warehouse management.
[0034] The multi-level vehicle includes three main sub-assemblies, namely a base carriage assembly, a vertical column assembly, and a lifting assembly. The base carriage assembly allows movement along an X-axis, positioning the multi-level vehicle at different locations within the warehouse racking system. The base carriage assembly includes a base frame, one or more drive motors, and one or more gearbox systems, all of which contribute to the vehicle's movement on a floor of the warehouse, or along a track such as rails (which may be laid on the floor of the warehouse, or along sides of the two opposite and corresponding storage levels in the warehouse racking system). The vertical column assembly, affixed to the base carriage assembly, includes a guiding structure comprising guiding columns or rails made of durable material such as aluminium, for guiding the lifting assembly in its vertical (Z-axis) movement. The lifting assembly includes a lifting carriage, which moves along the Z-axis, and a load handling mechanism, which can travel, and/or extend and retract in the Y-axis to handle store or retrieve the cartons, totes, baskets, trays, crates, bins, etc (referred to as “storage bin”). The load handling mechanism may be configured in such a manner that it can be optionally detached from the lifting carriage and be replaced or substituted by another load handling mechanism as per the requirement. The vertical column assembly is responsible for positioning the lifting assembly at the required vertical location within the warehouse racking system. The vertical column assembly may optionally include one or more sensors for positioning the lifting assembly. The multi-level vehicle may optionally include a vehicle control unit which controls movements of the multi-level vehicle (such as, along the X-axis). This also allows the multi-level vehicle to access both single-deep and multi-deep (such as, double-deep and triple-deep) locations within the warehouse racking system.
[0035] Each assembly within the multi-level vehicle is designed with specific mechanical components for efficient operation. When a storage bin is located at a specific (X, Y and Z) position, the multi-level vehicle moves on the floor or along the track to reach that point along the X-direction. At the same time while the multi-level vehicle is in motion, the lifting assembly moves vertically to reach the desired Z-height (or Z position). Once at the desired position, the load handling mechanism extends or travels to the location (or to necessary multi-deep location) to either retrieve or place the storage bin within the warehouse racking system.
[0036] The material handling system, designed for facilitating storage, retrieval, and picking operations in a multi-level warehouse racking system, includes the multi-level vehicle, with the base carriage assembly for navigating along the X-axis, the vertical column assembly aiding in vertical movement along the Z-axis, and the lifting assembly comprising the load handling mechanism that can extend or retract to reach the Y-coordinate within the warehouse racking system. The warehouse racking system is multi-tiered and structured to store a multitude of storage bins in a space-efficient manner. The warehouse racking system is designed to accommodate traversal and operation of the multi-level vehicle. The system includes a controller which issues storage and retrieval instructions to the vehicle control unit of the multi-level vehicle. The instructions include the precise X, Y, and Z coordinates of the storage bin and the task to be performed by the multi-level vehicle. The multi-level vehicle is directed by a vehicle control unit, which receives the said coordinates and controls movements of the multi-level vehicle accordingly. The vehicle control unit also actuates the load handling mechanism of the lifting assembly to handle the storage bin based on the instruction type i.e., either retrieval or storage. After completion of the task, the vehicle control unit may confirm to the controller that the task has been completed. Each of these components works in a synchronous manner to fulfil the objective of the material handling system, which is to efficiently perform storage, retrieval, or order picking operations within a multi-level warehouse racking system.
[0037] In operation, the material handling system initiates the process once the controller issues an instruction for the retrieval or storage or picking of a storage bin within a multi-level warehouse racking system, which also comprises the specific coordinates of location of the storage bin within the warehouse racking system, where 'X' corresponds to the horizontal position along the aisle, 'Y' signifies the depth within the rack, and 'Z' designates the vertical position or height within the rack. Subsequently, the vehicle control unit directs the multi-level vehicle to navigate along the X-axis on the warehouse floor or track to arrive at the determined X-coordinate. The lifting assembly of the multi-level vehicle initiates its vertical movement along the Z-axis, to the specified Z-coordinate. The multi-level vehicle and its lifting assembly simultaneously move towards the designated X and Z coordinates respectively, the load handling mechanism of the lifting assembly is then actuated to store and retrieve the storage bins by extending, retracting, or travelling to the determined Y-coordinate. If the received instruction is for the retrieval of a storage bin, the load handling mechanism grasps/lifts the storage bin and subsequently retracts or travels back, thus facilitating the extraction of the storage bin from the rack. Conversely, for a storage instruction, the load handling mechanism, having the storage bin, extends or travels towards the designated storage location. Upon reaching this location, the mechanism releases the storage bin and then retracts or travels back. After completion of the task, the vehicle control unit confirms to the controller that the task has been performed. This sequence of steps is iteratively performed for each subsequent instruction that the material handling system creates, thus enabling the efficient handling of storage and retrieval operations within a multi-level warehouse racking system.
[0038] The multi-level vehicle of the present disclosure offers flexibility in design, particularly concerning its height. The lifting assembly of the multi-level vehicle can be moved vertically to meet the warehouse's specific requirements and can fetch multiple storage levels within the warehouse racking system. The multi-level vehicle enhances the functionality of AS/RS in warehouses. By single-handedly enabling access to storage units in both horizontal and vertical directions, the multi-level vehicle provides an efficient solution for medium throughput requirements, balancing cost, and operational efficiency.
[0039] Referring to FIGS. 1A-1C, in combination, illustrated are different views of a multi-level vehicle 100, in accordance with one or more exemplary embodiments of the present disclosure. The multi-level vehicle 100 is designed to function autonomously within an Automated Storage and Retrieval System, enhancing the system's efficiency by providing access to multiple storage levels in a warehouse racking system. In particular, the multi-level vehicle 100 is configured to navigate both horizontally and vertically, using its three main sub-assemblies, each operating at a distinct dimension of movement. The mechanical design of the multi-level vehicle 100 allows it to position itself accurately at designated locations within the warehouse racking system, and to store or retrieve goods as required.
[0040] In an embodiment of the present disclosure, the multi-level vehicle 100 is a multi-level shuttle (with the two terms being interchangeably used without any limitations) configured for horizontal movements on tracks (such as tracks 10 as shown in FIG. 1A) along an aisle of the warehouse racking system. It may be understood that although, in the illustrated embodiments, the multi-level vehicle 100 is depicted to be traveling on the tracks 10; in other embodiments, the multi-level vehicle 100 may be configured to traverse on warehouse floor, or the like, without departing from the spirit and the scope of the present disclosure. In the present configuration, the multi-level shuttle 100 can service multiple storage levels in the warehouse racking system. In an exemplary configuration, the multi-level shuttle 100 may be configured to service 4 to 7 storage levels. In another exemplary configuration, the warehouse racking system may include at least one lift, typically at one of end locations of the track, to carry the multi-level shuttle 100 to the desired storage level(s) in order to serve more storage levels using the same multi-level shuttle 100.
[0041] As illustrated, the multi-level vehicle 100 includes various mechanisms, each serving a specific function. Specifically, the multi-level vehicle 100 includes three sub-assemblies: a base carriage assembly 200 for horizontal movement along an X-axis of the warehouse racking system; a vertical column assembly 300 affixed to the base carriage assembly 200 and configured for providing for vertical movement along a Z-axis; and a lifting assembly 400 configured for vertical movement along the vertical column assembly and configured for storage and retrieval operation (as discussed later in more detail). Each of these sub-assemblies are integrated to serve specific functions, for effective material handling and improved operational efficiency.
[0042] Referring to FIG. 2, illustrated is a perspective view of the base carriage assembly 200, in accordance with one or more exemplary embodiments of the present disclosure. The base carriage assembly 200 forms the foundational structure of the multi-level vehicle 100. The base carriage assembly 200 is responsible for facilitating the horizontal movements of the multi-level vehicle 100 on the tracks along an aisle of the warehouse racking system. As illustrated, the base carriage assembly 200 includes a base frame 202 which supports weight and operations of other components of the multi-level vehicle 100. The base frame 202 may be made from resilient material designed to ensure structural integrity while enduring the stresses and loads imposed during operations of the multi-level vehicle 100. The strength and durability of the base frame 202 ensure that it can accommodate and support the other two major assemblies of the multi-level vehicle 100, i.e., the vertical column assembly 300 and the lifting assembly 400.
[0043] The base carriage assembly 200 also includes a plurality of drive wheels 210 attached to the base frame 202. These drive wheels 210 provide the primary means of horizontal movement for the multi-level vehicle 100 along the X-axis. The base carriage assembly 200 further includes a drive mechanism 204, which is operatively coupled to at least one of the plurality of drive wheels 210. This coupling ensures transfer of power from the drive mechanism 204 to the drive wheels 210, enabling controlled movement of the multi-level vehicle 100. In the present configuration, the drive mechanism 204 may include at least one drive motor 212, which serves as the primary source of rotational power. The drive motor 212 is connected to at least one drive gearbox 214, which functions to modify the rotational speed and torque output from the drive motor 212 to match the requirements of the multi-level vehicle 100 for efficient operation. The drive mechanism 204 also includes at least one drive shaft 216, which is mechanically coupled to the drive motor 212 via the drive gearbox 214. This arrangement allows the rotational force generated by the drive motor 212 to be transmitted through the drive gearbox 214 and along the drive shaft 216 to drive at least one of the plurality of drive wheels 210. The combination of these components in the drive mechanism 204 enables the multi-level vehicle 100 to achieve controlled and efficient horizontal movement along the X-axis within the multi-level warehouse racking system 502. In some embodiments, the base frame 202 may include at least one idler shaft 218 along with idler wheels 220 may be installed on the other side to where the drive mechanism 204 is coupled. The idler shaft 218 and the idler wheels 220 act as a support structure for the load and for maintaining the stability during movement of the multi-level vehicle 100.
[0044] The base carriage assembly 200 further includes at least one lifting drive motor 230 and at least one lifting drive gearbox 232, for enabling the vertical movement for the multi-level vehicle 100, particularly in directing the lifting assembly 400 along the Z-axis. In an alternate embodiment, the lifting drive motor 230 and/or the lifting drive gearbox 232 may be mounted on the vertical column assembly 300 without departing from the scope and the spirit of the present disclosure. The lifting drive motor 230 is a dedicated motor unit installed within the base carriage assembly 200, to generate and provide the mechanical energy required for the upward and downward motion of the lifting assembly 400 along the vertical column assembly 300. The lifting drive gearbox 232 aids in the conversion of the high-speed, low-torque output of the lifting drive motor into a low-speed, high-torque force necessary for lifting. This conversion process offers precise control over the speed of vertical movement of the lifting assembly 400 along the vertical column assembly 300 in the multi-level vehicle 100, allowing for exact navigation of the multi-level vehicle 100 to different storage levels within the warehouse racking system.
[0045] Referring to FIGS. 3A and 3B, in combination, illustrated are different views of the vertical column assembly 300, in accordance with one or more exemplary embodiments of the present disclosure. The vertical column assembly 300 is a part of the structure of the multi-level vehicle 100, designed to support and facilitate vertical movement within the warehouse racking system. As shown in FIGS. 1A-1C, the vertical column assembly 300 is securely fixed to the base carriage assembly 200 forming an integrated unit. This integration allows for the base carriage assembly 200 to move the multi-level vehicle 100 along the X-axis, while the vertical column assembly 300 facilitates movement of the lifting assembly 400 within the multi-level vehicle 100 along the Z-axis. The vertical column assembly 300 is designed with a height that allows the multi-level vehicle 100 to service multiple levels within the warehouse racking system, thus covering multiple storage levels depending on the warehouse configuration. In an exemplary configuration, the multi-level vehicle 100 may be configured to service (reach) up to approximately 4 meters in height, to cover 4-7 storage levels (which usually vary from 0.5 m to 1 m in height).
[0046] As better illustrated in FIGS. 3A and 3B, the vertical column assembly 300 includes one or more guiding columns 302. The guiding columns 302 provide a framework for the lifting assembly 400 to move along the Z-axis. In an exemplary embodiment, the vertical column assembly 300 has four guiding columns 302 that are connected to form a stable and sturdy structure. The guiding columns 302 are typically made of a durable material like aluminium to ensure they can withstand the weight and continuous operation of the lifting assembly 400. Further, the vertical column assembly 300 includes a belt and pulley mechanism 304. The belt and pulley mechanism 304 may include pulleys 310 and belt clamps 312 (which may be in the form of chain-sprocket, rope, and the like) mounted at a top of the vertical column assembly 300, and a belt 314 which forms a loop, running over the pulleys 310 and the belt clamps 312 at the top of the vertical column assembly 300 and below the lifting assembly 400. In the belt and pulley mechanism 304, the pulleys 310 and the belt clamps 312 work in tandem with the lifting drive motor 230 and the lifting drive gearbox 232, located in the base carriage assembly 200, and thereby control the vertical movement of the lifting assembly 400 via the belt 314. Specifically, this mechanical connection enables the transmission of drive force from the lifting drive motor 230 and the lifting drive gearbox 232 to the lifting assembly 400, thereby facilitating the upward and downward movement of the lifting assembly 400 along the vertical column assembly 300.
[0047] Referring now to FIGS. 4A-4D, illustrated are different views of the lifting assembly 400, in accordance with one or more exemplary embodiments of the present disclosure. The lifting assembly 400, in the multi-level vehicle 100, is directly responsible for the storage and retrieval operations of goods within the warehouse racking system. The lifting assembly 400 includes several distinct parts, each serving a specific function in the operation of the multi-level vehicle 100. Specifically, the lifting assembly 400 includes a lifting carriage 410 and a load handling mechanism 420. The lifting carriage 410 forms the structural base to support the load handling mechanism 420 and is integral to the vertical movement of the lifting assembly 400 along the vertical column assembly 300. In an embodiment, the load handling mechanism 420 is adapted to be detachable from the lifting carriage 410. That is, in one implementation, the load handling mechanism 420 may be configured in such a manner that it can be optionally detached from the lifting carriage 410 and be replaced or substituted by any other load handling mechanism as per the requirement. For instance, telescopic gripper, forks, row cart, or telescopic arm, etc can be interchangeably used as the load handling mechanism 420. In another implementation, the load handling mechanism 420 may be configured to detach to be able to travel (away from the lifting assembly 400) along a storage rack to be utilized for storage and retrieval of the storage containers or the like.
[0048] The lifting carriage 410 includes a base frame 412 designed to bear the weight of the load handling mechanism 420 and the storage bin it handles. The design of the lifting carriage 410 is optimized for smooth and efficient movement along the vertical column assembly 300, ensuring precise positioning at various levels within the warehouse racking system. As shown, the lifting carriage 410 includes guide bearings 413 (or rollers) mounted at the base frame 412. The guide bearings 413 facilitate the vertical movement of the lifting carriage 410 along the vertical column assembly 300 by sliding smoothly along the vertical column assembly 300, ensuring a controlled, smooth movement along the Z-axis. The lifting carriage 410 also integrates at least one drive motor 414 and at least one gearbox 416 in the base frame 412, which serves as the power source for extension and retraction of the load handling mechanism 420. In particular, the load handling mechanism 420 is engineered to handle items located at either single-deep or multi-deep locations within the warehouse racking system. In an example implementation, as illustrated, the extension and retraction movement of the load handling mechanism 420 can be controlled by a system of belts 422 and pulleys 424, along with a drive shaft 426 and an idler shaft 428, which are powered separately by the drive motor 414 and the gearbox 416 controlling the extension and retraction of the load handling mechanism 420. It may be contemplated by a person skilled in the art that different arrangement of components may be implemented for the extension and retraction movement of the load handling mechanism 420 without departing from the spirit and the scope of the present disclosure.
[0049] In the illustrated embodiments, as shown in FIGS. 4A-4D, the load handling mechanism 420 is adapted as a telescopic gripper. In an example embodiment, as illustrated, the load handling mechanism 420 may include one or more pair of plates, particularly, in the FIGS 4A-4A-C three pairs of plates are demonstrated which includes a pair of moving plates 430, a pair of middle plates 432, and a pair of fixed plates 434. The moving plate 430 may feature a tooth-like structure at its base, is connected to the belt 422 and moves during extension and retraction of the load handling mechanism 420. The middle plate 432 and the fixed plate 434 remain stationary, providing guidance and support to the moving plate 430. It may be contemplated that the number of pairs of such plates may be increased (or decreased) based on whether its double deep or triple deep storage configurations, as implemented in the warehouse racking system, without any limitations. In the present implementation, the operation of the load handling mechanism 420 is further facilitated by constrained belts 436 and pulleys 438 which contribute to motion of the load handling mechanism 420, working in harmony with the belts 422 and the pulleys 424, hence controlling the extension and retraction of the load handling mechanism 420.
[0050] Referring back to FIGS. 1A-1C, the workings of the multi-level vehicle 100 is based on the synergistic operation of the base carriage assembly 200, the vertical column assembly 300, and the lifting assembly 400. Each of these assemblies plays a distinct role in the operation of the multi-level vehicle 100, to optimize the storage and retrieval operations with respect to items within the warehouse racking system. In the present implementation, with the base carriage assembly 200 configured to move along the tracks 10 installed at the base of the storage racks in the X-direction, the base carriage assembly 200 is capable of stopping at any point along the tracks 10, allowing for precise positioning of the multi-level vehicle 100 in relation to the storage racks. Subsequently, or simultaneously, the lifting assembly 400, along with the lifting carriage 410, moves along the vertical column assembly 300 in the Z-direction, reaching the appropriate level of the rack. This vertical movement is done with high precision, ensuring that the lifting assembly 400 is accurately aligned with the target storage level. Upon reaching the desired location, the load handling mechanism 420 within the lifting assembly 400 is then actuated to fetch or place an item from or into the storage rack.
[0051] Now referring to FIG. 5, the present disclosure further provides details of a material handling system (as represented by reference numeral 500), which is configured to streamline storage, retrieval, and picking operations in a multi-level warehouse racking system (depicted as a block and represented by reference numeral 502; and hereinafter referred to as “warehouse racking system 502”). Herein, the warehouse racking system 502 is a multi-tiered structure designed to accommodate a plurality of storage bins in a spatially efficient manner. The material handling system 500 includes the multi-level vehicle 100, which is configured to navigate within the warehouse racking system 502.
[0052] As discussed in the preceding paragraphs, the multi-level vehicle 100 includes three sub-assemblies: the base carriage assembly 200, the vertical column assembly 300, and the lifting assembly 400. The base carriage assembly 200 provides the multi-level vehicle 100 with the ability to navigate along the X-axis, and enables it to move horizontally across the aisle(s) within the warehouse racking system 502. The vertical column assembly 300 provides the multi-level vehicle 100 with the ability for vertical movement along the Z-axis, thereby helping reach different levels of the warehouse racking system 502. The lifting assembly 400 facilitates the access to the Y-coordinate within the warehouse racking system 502, and thereby allows the multi-level vehicle 100 to access storage bins located at various depths in the warehouse racking system 502. Specifically, the load handling mechanism 420 housed within the lifting assembly 400 is actuated to engage with storage bins, thereby performing either retrieval or storage operation in the material handling system.
[0053] In an exemplary embodiment, the material handling system 500 includes a controller 506 configured to receive or issue storage and retrieval orders for storage bins. These orders may originate from various sources such as a warehouse management system or from an operator input device (as represented by reference numeral 504), and are transmitted to the controller 506. The controller 506 is further configured to issue task instructions with X, Y, and Z coordinates of the storage bin within the warehouse racking system 502 to the multi-level vehicle 100. The material handling system 500 further includes a vehicle control unit 508 configured to control navigation and operation of the multi-level vehicle 100 in the warehouse racking system 502. The vehicle control unit 508 receives the task instruction comprising the task and the coordinates from the controller 506 and directs the movements of the multi-level vehicle 100 accordingly, ensuring the multi-level vehicle 100 moves horizontally along its aisle (X-coordinate) until the designated storage rack, the lifting assembly 400 elevates or descends to the right level (Z-coordinate), and that the load handling mechanism 420 extends, retracts or travels to the required depth (Y-coordinate) within the warehouse racking system 502 to store or retrieve the storage bin, based on the instruction. After completion of the task, the vehicle control unit 508 confirms to the controller 506 that the task has been performed.
[0054] Referring to FIG. 6, illustrated is a flowchart listing steps involved in a method (as represented by reference numeral 600) of operation of the material handling system 500, including the multi-level vehicle 100. At step 602, the method 600 includes issuing a task instruction to the vehicle control unit 508 of the multi-level vehicle 100 to retrieve or store a storage bin in the warehouse racking system 502. The instructions are a combination of the task involved and the specific coordinates (X, Y, Z) of the location for retrieval or storage of the storage bin within the warehouse racking system 502, wherein X corresponds to the horizontal position along the aisle, Y corresponds to the depth within the rack, and Z corresponds to the vertical position or height within the rack. At step 604, the method 600 includes controlling the base carriage assembly 200 of the multi-level vehicle 100 for horizontal movement along the X-axis. Herein, based on the instructions received by the vehicle control unit 508, the multi-level vehicle 100 moves along the X-axis to reach the determined X-coordinate by traversing the floor or the tracks (such as, the tracks 10) of the warehouse. At step 606, the method 600 includes initiating the vertical movement of the lifting assembly 400 of the multi-level vehicle 100 on the vertical column assembly 300 along the Z-axis. This enables the lifting assembly 400 to reach the determined Z-coordinate. It may be appreciated that the step 606 may take place simultaneous to the step 604, thus reducing the overall time for completing the two operations. At step 608, upon reaching the determined X and Z coordinates, the method 600 includes operating the lifting assembly 400 for storage and retrieval operation within the warehouse racking system 502. Specifically, the step 608 involves extending, retracting, or travelling the load handling mechanism 420 of the lifting assembly 400 along the Y-axis to the determined Y-coordinate for storing and retrieving the storage bin.
[0055] Furthermore, the method 600 includes either engaging and retracting the load handling mechanism 420 to retrieve the storage bin from the rack (if the order is to retrieve the storage bin), or extending and disengaging the load handling mechanism 420 to drop the storage bin at the appropriate location within the rack and then retracting the load handling mechanism 420. Furthermore, the method 600 includes directing the vehicle control unit 508 to confirm to the controller 506 that the task has been completed, i.e., the storage bin has been successfully retrieved or stored. These steps may be contemplated to be required for completing the desired operation by the multi-level vehicle 100 within the material handling system 500.
[0056] The material handling system 500, equipped with the multi-level vehicle 100, makes efficient use of the available space within the multi-level warehouse racking system 502. The material handling system 500, with its coordinated components, not only streamlines the warehouse operations but also enhances overall efficiency, proving to be a viable solution for large-scale warehouse management. Further, the overall design and operation of the multi-level vehicle 100 demonstrate several advantages over the prior-art. By incorporating the vertical column assembly 300 and the lifting assembly 400 which can traverse along the said vertical column assembly 300 to reach multiple levels of the warehouse racking system 502, the material handling system 500 can achieve multi-level operation, addressing the limitations of mini-load crane based ASRS and prior shuttle systems that are suitable and cater to either low or very high throughput requirements, respectively. The application of the multi-level vehicle 100 over shuttle systems which require a separate shuttle at each level leads to significant cost savings in terms of material cost as well as installation cost, while also reducing any idle time of material handling equipment. It also requires lesser maintenance as compared to the shuttle system. The application of the multi-level vehicle over mini-load crane based ASRS systems, provides for a material handling equipment which comparatively, can be easily installed and requires lesser space in a racking system. Further, the modular design of the multi-level vehicle 100 allows for customization of its vertical reach. Specifically, the height of the vertical column assembly 300 can be adjusted to service a variable number of storage levels within the warehouse racking system 502. This adaptability enables the multi-level vehicle 100 to be tailored to the specific needs of a customer's warehouse operations. Thus, the multi-level vehicle 100 of the present disclosure provides an efficient solution for medium to high throughput warehouse systems, mitigating many of the shortcomings of the existing technologies.
[0057] The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present disclosure and its practical application, to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated.
,CLAIMS:WE CLAIM:
1. A multi-level vehicle for use in a multi-level warehouse racking system, the multi-level vehicle comprising:
a base carriage assembly configured for horizontal movement along an X-axis of the multi-level warehouse racking system;
a vertical column assembly affixed to the base carriage assembly, the vertical column assembly extends along a Z-axis; and
a lifting assembly configured for vertical movement along the vertical column assembly, the lifting assembly further configured for storage and retrieval operation.

2. The multi-level vehicle as claimed in claim 1, wherein the base carriage assembly comprises a base frame, a plurality of drive wheels, and a drive mechanism operatively coupled to at least one of the plurality of drive wheels, for enabling the horizontal movement of the multi-level vehicle along the X-axis.

3. The multi-level vehicle as claimed in claim 2, wherein the drive mechanism comprises at least one drive motor, at least one drive gearbox, and at least one drive shaft, wherein the drive shaft is coupled to the at least one drive motor via the at least one drive gearbox to drive the at least one of the plurality of drive wheels.

4. The multi-level vehicle as claimed in claim 1, wherein the vertical column assembly comprises one or more guiding columns and a belt and pulley mechanism for controlling the vertical movement of the lifting assembly.

5. The multi-level vehicle as claimed in claim 1, wherein the lifting assembly comprises a lifting carriage, and a load handling mechanism supported on the lifting carriage, wherein the load handling mechanism is configured to travel, or extend and retract along a Y-axis for storing and retrieving a storage bin.

6. The multi-level vehicle as claimed in claim 5, wherein the load handling mechanism is adapted as a telescopic gripper.

7. The multi-level vehicle as claimed in claim 5, wherein the load handling mechanism is adapted to be detachable from the lifting carriage.

8. A material handling system comprising:
a multi-level vehicle configured to navigate within a multi-level warehouse racking system of the material handling system, the multi-level vehicle comprising:
a base carriage assembly configured for horizontal movement along an X-axis of the multi-level warehouse racking system;
a vertical column assembly affixed to the base carriage assembly, the vertical column assembly extends along a Z-axis; and
a lifting assembly configured for vertical movement along the vertical column assembly, the lifting assembly configured for storage and retrieval operation;
a controller configured to receive or issue a task instruction for storage and retrieval orders for storage bins from within the multi-level warehouse racking system, including X, Y, and Z coordinates of the storage bin; and
a vehicle control unit configured to control navigation and operation of the multi-level vehicle to facilitate either retrieval or storage of the storage bin, based on the task instruction.

9. The material handling system as claimed in claim 8, wherein the lifting assembly comprises a lifting carriage, and a load handling mechanism supported on the lifting carriage, wherein the load handling mechanism is configured to travel, or extend and retract along a Y-axis for storing and retrieving a storage bin.

10. A method for retrieval or storage of a storage bin in a multi-level warehouse racking system, the method comprising:
issuing a task instruction to a multi-level vehicle, to retrieve or store the storage bin in the multi-level warehouse racking system;
controlling a base carriage assembly of the multi-level vehicle for horizontal movement along the X-axis;
initiating a vertical movement of a lifting assembly of the multi-level vehicle on a vertical column assembly along a Z-axis; and
operating the lifting assembly for storage and retrieval operation within the multi-level warehouse racking system.