Description:BACKGROUND
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Indian provisional patent application no. 202341078248 filed on November 17, 2023, the complete disclosure of which, in their entirety, is herein incorporated by reference.
Technical Field
[0002] The embodiments herein generally relate to warehouse storage devices, more particularly to a system and a method for storing and retrieving objects in automated storage and retrieval systems.
Description of the Related Art
[0003] Efficiency, accuracy, and speed are crucial in logistics sectors, where warehouse management plays a crucial role. As a result, modern warehouses are progressively integrating technology, including automated machines. The need to efficiently manage intricate inventory systems, cut down on errors, and satisfy rising customer demands is what is driving this shift. Utilizing specialist equipment is essential to current warehouse management systems. Autonomous guided vehicles, shuttles, and stacker cranes are a few of the main equipment utilized to manage many facets of warehouse operations. These devices are made to maximize efficiency throughout the operation by streamlining the procedures of order fulfilment, retrieval, and storage. Guide rails are used in the aisles of the warehouse to make it easier for this equipment to move around and guarantee accuracy in their operations. The machines move objects with extreme precision and control. The guide rails act as navigational routes. This is especially important in warehouse settings where the product is packed closely together and inaccuracies in movement cause serious disruptions and inefficiency.
[0004] The existing systems have two separate approaches: the first is the single stacker crane strategy, and the second is the approach using many shuttles or autonomous guided vehicles. When using the single stacker crane, one stacker crane is in charge of managing items down the whole aisle and on various levels of the storage racks. The setup is made simpler and easier to handle when tasks are centralized onto a single machine. With this method, the operation time is long because only one machine is in charge of all duties. A single machine becomes a process bottleneck if it is in charge of organizing, retrieving, and fulfilling orders for every article in an aisle. The warehouse's overall efficiency is negatively impacted by any delays or inefficiencies. Key locations in the warehouse where items are placed onto or taken off of the stacker crane are called access stations. These access stations have long wait times when using the single stacker crane approach as everything has to go through the same machine.
[0005] The other strategy is to station shuttles or self-guiding vehicles at every level of the storage racks. By using this strategy, the workload is distributed more fairly and access station wait times are shortened. Higher costs are associated with having multiple shuttles or autonomous guided vehicles at different rack levels. The overall maintenance burden rises as more of these machines are put into service because they need maintenance. This may have an impact on the warehouse's spending plan and resource allocation. Although the goal of this strategy is to shorten wait times and address supply queue problems, it might not totally resolve them. If there are delays in communication and synchronization between the machines, or if the system is not well-coordinated, these factors may still affect the operation time. With this method, a high supply queue that indicates lengthy wait times for objects to be processed can still be problematic.
[0006] The object highlights the issues with the supply queue and operation time in both of these methods. Operation time is a crucial metric for assessing efficiency because it refers to the amount of time it takes the warehouse machines to finish their tasks. Because there may be bottlenecks in the first approach, where a single stacker crane manages all tasks, the operation time may be extended. Under the second approach, maintenance and machine coordination can still affect operation time even though the workload is distributed differently. Another major worry is the supply line. It accounts for any delays or waiting periods that items might encounter while going through the warehouse procedures. A long supply line may be a sign of operational inefficiencies in the warehouse, which could cause delays in order fulfilment and possibly unhappy customers.
[0007] Nonetheless, in order to increase accuracy and efficiency, contemporary warehouse management systems have been developed to include cutting-edge equipment. For the purpose of handling items in the warehouse, autonomous guided vehicles, shuttles, and stacker cranes are essential. The section highlights the trade-offs between the two primary strategies for deploying these machines. The main issues are cost, maintenance, operational efficiency, and the possible effects of supply line problems on the warehouse's overall performance.
[0008] Accordingly, there remains a need for a system and a method for optimizing efficiency, accuracy, and speed in the modern warehouse management system.
SUMMARY
[0009] Embodiments herein provide a storage facility for storing and retrieving objects in automated storage and retrieval systems. The storage facility includes one or more three-dimensional rack assembly, one or more top rail profiles, one or more bottom rail profiles. The one or more three-dimensional rack assembly include one or more structured uprights, one or more structured beams, one or more deck structures and one or more support profiles. The one or more structured uprights are mounted on the floor at a defined horizontal distance and extended to a defined vertical height. The one or more structured beams are horizontally mounted between the adjacent structured upright at a defined vertical distance using one or more end connectors. The one or more deck structures are mounted on the one or more structured beams. The deck structure includes self-lock ends that couple the deck structure on the one or more structured beams. The one or more support profiles are mounted between the one or more uprights. The one or more top rail profiles are mounted on the one or more uprights at defined levels of the three-dimensional rack assembly. The one or more bottom rail profiles are mounted on the one or more uprights at defined levels of the three-dimensional rack assembly.
[0010] In some embodiments, the one or more beams include a box structure section that includes one or more embossing on a web section at a defined distance and a C-joint.
[0011] In some embodiments, the structured upright includes a first channel, a second channel, one or more embossing and a pair of lips. The first channel mounts the one or more supporting profiles. The one or more supporting profiles are mounted on the first channel using at least one of fasteners or welding. The second channel mounts the one or more structured beams using the one or more end connectors. The one or more structured beams are mounted on the second channel using at least one of welding or one or more clip locks. The one or more embossing are located on the second channel. The pair of lips are located on an open end of the first channel. The open end of the first channel is extended with the second channel.
[0012] In some embodiments, the storage facility includes one or more storage rows, one or more aisle rows, one or more object transfer rows and one or more stopper profiles. The one or more storage rows provide one or more storage positions for the objects. The one or more storage rows are formed by mounting the one or more deck structures between at least two structured beams that are mounted parallelly with the one or more structured uprights. The one or more storage rows form a three-dimensional rack. The one or more aisle rows provide a runway for an automatic storage and retrieval machine using at least one of the one or more top rail profiles or the one or more bottom rail profiles. The one or more aisle rows are formed between the at least two three-dimensional racks that are positioned parallelly. The one or more object transfer rows provide object handling positions for the automated storage and retrieval machine. The one or more stopper profiles are mounted on the one or more structured beams that are mounted outside of the three-dimensional rack assembly.
[0013] In some embodiments, the one or more structured uprights are mounted on the floor using one or more base plates. The base plate includes at least one of a base and a ‘c’ structured channel to mount the structured upright.
[0014] In some embodiments, the one or more top rail profiles are mounted on the one or more structured uprights of at least one side of an aisle row of the three-dimensional rack assembly. The one or more top rail profiles are mounted on the one or more uprights using at least one of fasteners, welding, one or more resting plates.
[0015] In some embodiments, the top rail profile includes a first rail and a second rail. The first rail accommodates one or more drive wheels of the automated storage and retrieval machine. The first rail is a ‘C’ structure extended with one or more lips. The first rail includes one or more stiffeners. The second rail is mounted with the first rail using one or more rail coupling plates. The second rail is a ‘C’ structure extended with one or more lips.
[0016] In some embodiments, the one or more bottom rail profiles are mounted on at least one side of an aisle row of the three-dimensional rack assembly. The one or more bottom rail profiles are mounted on the one or more uprights using at least one of fasteners, welding, one or more rail mounting plates.
[0017] In some embodiments, the bottom rail profile is a ‘L’ structure extended with one or more lips. The bottom rail profile accommodates one or more guide wheels of the automated storage and retrieval machine.
[0018] In some embodiments, the storage facility includes one or more aisle coupling profiles are mounted on the second channel of the one or more structured uprights that are positioned on the one or more aisle row. The one or more aisle coupling profiles are mounted on a top surface of the one or more top rail profiles.
[0019] In another aspect, a system for storing and retrieving objects in automated storage and retrieval systems is provided. The system includes a storage facility and one or more automated storage and retrieval machines. The storage facility includes one or more rail profiles on one or more aisle rows at a defined distance. The one or more rail profiles are mounted on one or more structured uprights of at least one side of an aisle row of the storage facility. The one or more automated storage and retrieval machines are mounted on the one or more rail profiles. The one or more automated storage and retrieval machines run on the one or more rail profiles and handle objects between one or more storage positions and one or more object handling positions of the storage facility. When in operation, the system operates the automated storage and retrieval machine to handle the objects between defined storage rows and defined object transfer rows on the aisle row. The automated storage and retrieval machine includes a work handling platform that is operated to handle the objects at a defined storage rows of the storage facility.
[0020] In some embodiments, the storage facility includes one or more storage rows, one or more aisle rows, one or more object transfer rows and one or more stopper profiles. The one or more storage rows provide the one or more storage positions for the objects. The one or more storage rows are formed by mounting one or more deck structures between at least two structured beams that are mounted parallelly with one or more structured uprights. The one or more storage rows form a three-dimensional rack. The one or more aisle rows provide a runway for the automatic storage and retrieval machine. The one or more aisle rows are formed between the at least two three-dimensional racks that are positioned parallelly. The one or more object transfer rows provide one or more object handling positions for the automated storage and retrieval machine. The one or more stopper profiles are mounted on one or more structured beams are mounted outside of the three-dimensional rack assembly.
[0021] In some embodiments, the automated storage and retrieval machine includes the work handling platform, a first drive assembly and a second drive assembly. The work handling platform is mounted on a structured frame of the automated storage and retrieval machine. The work handling platform runs on the structured frame to handle the objects between at least one of the defined storage row levels and the one or more object handling positions. The structured frame includes at least one of a base frame, one or more pillars, a top supporting frame or a control panel frame. The first drive assembly is mounted on the top supporting frame to operate the automated storage and retrieval machine on the one or more rail profiles. The second drive assembly is mounted on at least one of the top supporting frame to operate the work handling platform on the one or more pillars of the structured frame.
[0022] In some embodiments, the first drive assembly includes one or more first wheels, first driving motor and one or more first guide wheels. The one or more first wheels are mounted on at least one of the top supporting frame or the one or more pillars using at least one of one or more mounting plates, bearings or spacers. The one or more first wheels run on the one or more rail profiles of the storage facility. The first driving motor is coupled with the at least one first wheel using at least one of the mounting plates, gear assembly, a drive shaft, bearing or spacers. The one or more first guide wheels are mounted on at least one of the top supporting frame or the one or more pillars using at least one of one or more mounting plates, bearings or spacers. The one or more first guide wheels run on the one or more rail profiles of the storage facility.
[0023] In some embodiments, the second drive assembly includes at least one of a ball screw rod assembly or a pulley assembly and a second driving motor. The at least one of the ball screw rod assembly or the pulley assembly is coupled with the work handling platform to operate the work handling platform on the one or more pillars. The second driving motor is mounted on the top supporting frame and coupled with at least one of a ball screw rod assembly or a pulley assembly using at least one of the mounting plates, gear assembly, a drive shaft, bearing or spacers.
[0024] In some embodiments, the work handling platform includes one or more plates, an object picker and a guide wheel assembly. The one or more plates form a housing. The object picker handles the objects. The guide wheel assembly is mounted on each side of the housing to guide the work handling platform on the one or more pillars when the work handling platform is operated by the second drive assembly. The second drive assembly is coupled with the work handling platform using at least one of the belts or chains of the second driving assembly using one or more holding plates mounted on each side of the housing.
[0025] In some embodiments, the object picker is mounted on the housing of the work handling platform. The object picker includes an arm assembly that includes one or more supporting plates, a pair of arm plate assembly and a driving assembly. The one or more supporting plates and one or more supporting tubes that form a housing. The pair of arm plate assembly is mounted on the middle portion of the housing. The arm plate assembly includes at least one of (a) a base plate that is mounted on the housing platform, (b) one or more middle plates that are coupled with the base plate using one or more sliding assembly or (c) an end plate that is coupled with the at least one of the middle plate using the one or more sliding assembly. The end plate is coupled with one or more fingers to handle the objects on the storage facility. The driving assembly is mounted on at least one end portion of the housing to drive the pair of arm plate assembly using at least one of the sliding assembly mounted on the pair of arm plate assembly, a driving motor, a gear assembly, a drive shaft, chains or belts. The arm assembly is at least one of (a) moved simultaneously or (b) moved sequentially on the one or more aisle rows or on the automated storage and retrieval machine.
[0026] In some embodiments, the object picker of the object picker includes a moving cart that handles the objects between at least one of the one or more storage rows, one or more object transfer rows or the automated storage and retrieval machine. The moving cart is at least one of (a) moved simultaneously or (b) moved sequentially on the one or more aisle rows or on the automated storage and retrieval machine.
[0027] In some embodiments, the work handling platform mounted on the automatic storage and retrieval machine handles the objects on the one or more storage rows that are located on each side of the aisle row of the storage facility.
[0028] In some embodiments, the storage rows that are formed vertically on the one or more structured uprights to form one or more storage row levels. The one or more storage rows and the one or more aisle rows are mounted in traverse on the storage facility.
[0029] In some embodiments, the system includes at least one automatic storage and retrieval machine for each (a) at least five storage row levels and (b) aisle row of the storage facility.
[0030] In another aspect, a method of storing objects to a storage position on a storage facility using an automated storage and retrieval machine is provided. The method includes (a) placing the objects on an object handling position on an object transfer row of the storage facility using one or more conveyors, (b) moving the automated storage and retrieval machine to an object transfer row that is associated with the object handling position using one or more rail profiles of the storage facility, (c) placing the object on a work handling platform from the object handling position using an object picker of the work handling platform, (d) moving the object on at least one of (i) the aisle row on the one or more rail profiles to the storage position using the automated storage and retrieval machine or (ii) the automated storage and retrieval machine to a storage row level of the storage facility that is associated with the storage position using the work handling platform and (e) placing the object on the storage position by removing the object from the automated storage and retrieval machine using the object picker of the automated storage and retrieval machine. When in operation, the object is at least one of (a) moved simultaneously or (b) moved sequentially on the aisle row or the automated storage and retrieval machine.
[0031] In some embodiments, the method includes (a) placing the objects on a lift assembly using the conveyors and (b) moving the objects between the object handling position that is associated with a desired storage row level and the conveyor assembly of the storage facility using the lift assembly.
[0032] In some embodiments, the storage facility is mounted with at least one automatic storage and retrieval machine for each (a) at least five storage row levels and (b) aisle row of the storage facility.
[0033] In another aspect, a method of retrieving objects from a storage position on a storage facility using an automated storage and retrieval machine is provided. The method includes (a) moving the automated storage and retrieval machine to a storage row level that is associated with the storage position using one or more rail profiles of the storage facility, (b) placing the object on the work handling platform by removing the object from the storage position using an object picker of the automated storage and retrieval machine, (c) moving the object on at least one (i) the aisle row on the one or more rail profiles to an object transfer row associated with an object handling position, or (ii) the automated storage and retrieval machine to the object handling position using the work handling platform and (d) placing the object on the object handling position by removing the object from the automated storage and retrieval machine using the object picker of the automated storage and retrieval machine. When in operation the object is at least one of (a) moved simultaneously or (b) moved sequentially on the aisle row or the automated storage and retrieval machine.
[0034] In some embodiments, the method includes (a) placing the objects on a lift assembly using conveyors and (b) moving the objects between the object handling position that is associated with a desired storage row level and the conveyor assembly of the storage facility using the lift assembly.
[0035] In some embodiments, the storage facility is mounted with at least one automatic storage and retrieval machine for each (a) at least five storage row levels and (b) aisle row of the storage facility.
[0036] In another aspect, a method of storing and retrieving objects on a storage facility using one or more automated storage and retrieval machines is provided. The method includes (a) placing the objects on one or more object handling positions on one or more object transfer row of the storage facility using one or more conveyors, (b) moving the one or more automated storage and retrieval machines on one or more aisle rows between at least one of one or more storage positions or the one or more object handling positions using one or more rail profiles, (c) placing the objects on a work handling platform of the one or more automated storage and retrieval machines from at least one the one or more storage positions or the one or more object handling positions using an object picker of the one or more automated storage and retrieval machines, (d) moving the objects to at least one of the one or more storage positions or the one or more object handling positions associated with at least one of the one or more aisle rows or the one or more object transfer rows using the one or more automated storage and retrieval machines and (e) placing the objects on at least one of the one or more storage positions or the one or more object handling positions from the one or more automated storage and retrieval machines using the work handling platform. When in operation, the object is at least one of (a) moved simultaneously or (b) moved sequentially on the one or more aisle rows or the one or more automated storage and retrieval machines.
[0037] In some embodiments, the method includes (a) placing the objects on one or more lift assembly using the one or more conveyors and (b) moving the objects between the one or more object handling positions that are associated with a desired storage row level and the one or more conveyor assembly of the storage facility using the one or more lift assembly.
[0038] In some embodiments, the storage facility is mounted with at least one automatic storage and retrieval machine for each (a) at least five storage row levels and (b) aisle row of the storage facility.
[0039] In some embodiments, the storage facility includes one or more three-dimensional rack assembly, one or more storage rows, one or more aisle rows, one or more object transfer rows and one or more stopper profiles. The one or more three-dimensional rack assembly are formed by at least one of one or more structured uprights, one or more structured beams, one or more deck structures, one or more rail profiles, one or more stopper profiles or one or more supporting profiles. The three-dimensional rack assembly includes one or more storage rows that are formed vertically on the one or more structured uprights to form one or more storage row levels. The one or more storage rows that provide one or more storage positions for the objects. The one or more aisle rows provide a runway for the one or more automatic storage and retrieval machines. The one or more rail profiles are mounted on the one or more aisle rows at a defined distance. The one or more rail profiles are mounted on one or more structured uprights of at least one side of the aisle row of the storage facility. The one or more aisle rows are formed between the at least two three-dimensional racks that are positioned parallelly. The one or more storage rows and the one or more aisle rows are mounted in traverse on the storage facility. The one or more object transfer rows provide the one or more object handling positions for the one or more automated storage and retrieval machines. The one or more stopper profiles are mounted on the one or more structured beams that are mounted outside of the one or more three-dimensional rack assembly.
[0040] In some embodiments, the automated storage and retrieval machine includes the work handling platform, a first drive assembly and a second drive assembly. The work handling platform is mounted on a structured frame of the automated storage and retrieval machine. The work handling platform runs on the structured frame to handle the objects between the one or more storage row levels. The structured frame includes at least one of a base frame, one or more pillars, a top supporting frame or a control panel frame. The first drive assembly is mounted on the top supporting frame to operate the automated storage and retrieval machine on the one or more rail profiles. The second drive assembly is mounted on at least one of the top supporting frame to operate the work handling platform on the one or more pillars of the structured frame.
[0041] In some embodiments, the work handling platform includes one or more plates, an object picker, a guide wheel assembly. The one or more plates that form a housing. The object picker handles the objects. The guide wheel assembly is mounted on each side of the housing to guide the work handling platform on the one or more pillars when the work handling platform is operated by the second drive assembly. The second drive assembly is coupled with the work handling platform using at least one of the belts or chains of the second driving assembly using one or more holding plates mounted on each side of the housing.
[0042] In some embodiments, the object picker includes at least one of an arm assembly or a moving cart. The arm assembly is mounted on a middle portion of the housing. The arm assembly handles the objects on at least one of the one or more storage rows, the one or more object transfer rows or the automated storage and retrieval machine. The moving cart handles the objects between at least one of the one or more storage rows, one or more object transfer rows or the automated storage and retrieval machine. At least one of the arm assembly or the moving cart is at least one of (a) moved simultaneously or (b) moved sequentially on the one or more aisle rows or on the automated storage and retrieval machine.
[0043] In some embodiments, the automated storage and retrieval machine determines the location and the level of the encoded object by scanning the one or more embedded codes on the storage facility. In some embodiments, the encoded object is placed on the location when the one or more embedded codes are matched with the location details received from the centralized computing device. In some embodiments, the operation is reversed for retrieval of the objects from the storage rack. In some embodiments, the proposed structural design is smaller than any commercial design. In some embodiments, the automated storage and retrieval machine manufacturing process is simple and made with sheet metal. The cost of the automated storage and retrieval machine is 25% to 50% less than any commercial device. In some embodiments, the speed of the automated storage and retrieval machine is between 1 meter/ second to 5 meter/ sec. The payload of the automated storage and retrieval machine 116 is in the range of 05 kilograms to 3000 kilograms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
[0045] FIGS. 1A illustrates an exemplary system view of an automated storage and retrieval system for performing storage and retrieval of objects using an automated storage and retrieval machine according to some embodiments herein;
[0046] FIG. 1B and FIG. 1C illustrates an exemplary view of a storage facility with one or more automated storage and retrieval machines according to some embodiments herein;
[0047] FIG. 2A illustrates an exemplary view of an automated storage and retrieval machine according to some embodiments herein;
[0048] FIG. 2B illustrates an exemplary view of an automated storage and retrieval machine with a ball screw rod assembly according to some embodiments herein;
[0049] FIG. 2C illustrates an exemplary view of an automated storage and retrieval machine with a pulley assembly according to some embodiments herein;
[0050] FIG. 3A illustrates an exemplary view of an automated storage and retrieval machine with an arm assembly according to some embodiments herein;
[0051] FIG. 3B illustrates an exemplary view of an automated storage and retrieval machine with a moving cart according to some embodiments herein; and
[0052] FIG. 4 is a flow diagram of a method of storing and retrieving objects on a storage facility using one or more automated storage and retrieval machines of FIG. 1 according to some embodiments herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0053] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0054] An objective of the current invention is to provide a device and method for handling objects between a set of levels in a storage rack automatically and that removes or at least lessens the limitations mentioned above. These goals are accomplished using the method described in the appended description. As mentioned, there remains a need device and method for transferring object containers in storage lanes automatically. Referring now to the drawings, and more particularly to FIG. 1 to FIG. 4, where similar reference characters denote corresponding features consistently throughout the figures, preferred embodiments are shown.
[0055] FIGS. 1A illustrates an exemplary system view of an automated storage and retrieval system for performing storage and retrieval of objects using an automated storage and retrieval machine 116 according to some embodiments herein. The automated storage and retrieval system includes a storage facility 100 and one or more automated storage and retrieval machines 116A-N. The storage facility includes one or more three-dimensional rack assembly 102A-N, one or more top rail profiles 104A-N, one or more bottom rail profiles 106A-N. The one or more three dimensional rack assembly 102A-N includes one or more structured uprights 108A-N, one or more structured beams 110A-N, one or more deck structures 112A-N, one or more support profiles 114A-N. The structured upright 108 includes a first channel 118, a second channel 120, one or more embossing 122A-N and a pair of lips. The one or more beams 110A-N include a box structure section includes one or more embossing 122A-N on a web section at a defined distance and a C-joint. The top rail profile 104 includes a first rail 132 and a second rail 134. In some embodiments, the one or more top rail profiles 104A-N and the one or more bottom rail profiles 108A-N are mounted on at least one side of the one or more aisle rows 126A-N. In some embodiments, the storage facility 100 comprises one or more storage rows 124A-N, the one or more aisle rows 126A-N, one or more object transfer rows 128A-N and one or more stopper profiles 130A-N.
[0056] The storage facility 100 includes one or more rail profiles 104A-N and 106A-N on one or more aisle rows 126A-N at a defined distance. In some embodiments, the one or more rail profiles 104A-N and 106A-N are mounted on one or more structured uprights 108A-N of at least one side of the aisle row 126 of the storage facility 100. The one or more automated storage and retrieval machines 116A-N are mounted on the one or more rail profiles 104A-N and 106A-N. The one or more automated storage and retrieval machines 116A-N run on the one or more rail profiles 104A-N and 106A-N and handle objects between one or more storage positions and one or more object handling positions of the storage facility 100. The automated storage and retrieval system operates the one or more automated storage and retrieval machines 116A-N to handle the objects between defined storage rows 124A-N and defined object transfer rows 128A-N on the aisle row 126. The automated storage and retrieval machine 116 includes a work handling platform 202 that is operated to handle the objects at defined storage rows 124A-N of the storage facility 100. The automated storage and retrieval system includes at least one automatic storage and retrieval machine for each (a) at least five storage row levels and (b) aisle row 126 of the storage facility 100
[0057] With reference to FIG. 1A, FIG. 1B and FIG. 1C illustrates an exemplary view of a storage facility 100 with one or more automated storage and retrieval machines 116A-N according to some embodiments herein. The one or more structured uprights 108A-N are mounted on the floor at a defined distance and extended to a defined vertical height. The one or more structured beams 110A-N are horizontally mounted between the adjacent structured upright 108A-N at a defined vertical distance using one or more end connectors. The one or more deck structures 112A-N are mounted on the one or more structured beams 110A-N. The deck structure comprises self-lock ends that couple the deck structure on the one or more structured beams 110A-N. In some embodiments, the one or more deck structures 112A-N arrest a movement of objects on the one or more deck structures 112A-N. The one or more support profiles 114A-N are mounted between the one or more structured uprights 108A-N.
[0058] The first channel 118 mounts the one or more supporting profiles 114A-N. In some embodiments, the one or more supporting profiles 114A-N are mounted on the first channel 118 using at least one of welding or fasteners. The second channel 120 mounts the one or more structured beams 110A-N using the one or more end connectors. In some embodiments, the one or more structured beams 110A-N are mounted on the second channel 120 using at least one of welding or the one or more clip locks. The one or more embossing 122A-N are located on the second channel 120. The pair of lips are located on an open end of the first channel 118. The open end of the first channel 118 is extended with the second channel 120. The one or more structured uprights 108A-N are mounted on the floor using one or more base plates. The base plate comprises at least one of a base and a ‘c’ structured channel to mount the structured upright 110. In some embodiments, the base plate mounts the structured upright 110 using at least one of the fasteners or welding.
[0059] In some embodiments, the one or more storage rows 124A-N provide one or more storage positions for the objects. The one or more storage rows 124A-N are formed by mounting the one or more deck structures 112A-N between at least two structured beams 110A-N that are mounted parallelly with the one or more structured uprights 108A-N. In some embodiments, the one or more storage rows 124A-N forms a three-dimensional rack 102. In some embodiments, the three dimensional rack 102 is extended to X length, Y width and Z height using at least one of the one or more structured uprights 108A-N, the one or more structured beams 110A-N or the one or more supporting profiles 114A-N. The one or more aisle rows 126A-N provide a runway for the automatic storage and retrieval machine 116 using at least one of the one or more top rail profiles 104A-N or the one or more bottom rail profiles 106A-N. The one or more aisle rows 126A-N are formed between the at least two three-dimensional rack 102 that are positioned parallelly.
[0060] The one or more object transfer rows 128A-N provide object handling positions for the automated storage and retrieval machine 116. The one or more stopper profiles 130A-N are mounted on the one or more structured beams 110A-N that are mounted outside of the three-dimensional rack assembly 102. The one or more top rail profiles 104A-N are mounted on the one or more structured uprights 108A-N at defined levels of the one or more three-dimensional rack assembly 102A-N. The one or more bottom rail profiles 106A-N are mounted on the one or more structured uprights 108A-N at defined levels of the one or more three-dimensional rack assembly 102A-N. The one or more top rail profiles 104A-N are mounted on the one or more structured uprights 108A-N of at least one side of an aisle row 126 of the three-dimensional rack assembly 102. In some embodiments, the one or more top rail profiles 104A-N is mounted on the one or more structured uprights 108A-N using at least one of fasteners, welding, or one or more resting plates. The one or more bottom rail profiles 106A-N are mounted on at least one of the aisle row 126 of the three dimensional rack assembly 102. In some embodiments, the one or more bottom rail profiles 106A-N are mounted on the one or more structured uprights 108A-N using at least one of fasteners, welding, and one or more rail mounting plates.
[0061] The first rail 132 accommodates one or more drive wheels of the automated storage and retrieval machine 116. In some embodiments, the first rail 132 is a ‘C’ structure extended with one or more lips. In some embodiments, the first rail 132 includes one or more stiffeners to provide strength and stability to the top rail profile 104 for the movement of the automated storage and retrieval machine 116. The second rail 134 is mounted with the first rail 132 on the one or more structured uprights 108A-N using one or more rail coupling plates. In some embodiments, the second rail 134 is a ‘C’ structure extended with one or more lips. The one or more bottom rail profiles 106A-N are mounted on at least one side of the aisle row 126 of the one or more three-dimensional rack assembly 102. In some embodiments, the one or more bottom rail profiles 106A-N is mounted on the one or more structured uprights 108A-N using at least one of fasteners, welding, and one or more rail mounting plates. In some embodiments, the bottom rail profile 106 is an ‘L’ structure extended with the one or more of lips. The bottom rail profile 106 accommodates one or more guide wheels of the automated storage and retrieval machine 116. In some embodiments, the storage facility 100 comprises a plurality of aisle coupling profile 136A-N that is mounted on the second channel 134 of the one or more structured uprights 108A-N that are positioned on the one or more aisle rows 126A-N. In some embodiments, the one or more aisle coupling profiles are mounted on a top surface of the one or more top rail profiles 104A-N.
[0062] With reference to FIGS. 1A to 1C, FIG. 2A illustrates an exemplary view of the automated storage and retrieval machine 116 according to some embodiments herein. The automated storage and retrieval machine 116 includes the work handling platform 202, a base frame 204, a plurality of pillars 206A-N, a top supporting frame 208, a control panel frame 210, a first drive assembly 212, a second drive assembly 214, a plurality of plates 216A-N, an object picker 218 and a guide wheel assembly 220. In some embodiments, the base frame 204, the plurality of pillars 206A-N, the top supporting frame 208 and the control panel frame 210 form a structured frame. The work handling platform 202 is mounted on the structured frame of the automated storage and retrieval machine 116 and runs on the structured frame to handle the objects between at least one of the defined storage row levels and the one or more object handling positions. The first drive assembly 212 is mounted on the top supporting frame 208 to operate the automated storage and retrieval machine 116 on the one or more rail profiles (104A-N and 106A-N). The first driving assembly 212 includes one or more first wheels, one or more first guide wheels, a first driving motor. The one or more first wheels are mounted with the first driving motor using at least one of bearings, cover plates, gear assembly or one or more spacers.
[0063] The one or more first wheels are mounted inside the one or more rail profiles 104A-N and 106A-N. In some embodiments, the one or more first wheels include at least one of one or more driving wheels or one or more non-driving wheels. In some embodiments, the one or more driving wheels are coupled with the first driving motor to operate the automated storage and retrieval machine 116 on the one or more rail profiles 104A-N and 106A-N. The one or more first guide wheels are mounted on the cover plates using at least one of one or more spacers, bearings or fasteners. In some embodiments, the one or more first guide wheels are mounted on the lips of the one or more rail profiles 104A-N and 106A-N. In some embodiments, the one or more first guide wheels are mounted with both the one or more driving wheels and the one or more non-driving wheels. In some embodiments, the one or more first guide wheels are mounted on at least one of the top supporting frame 208 or the one or more pillars 206A-N using at least one of one or more mounting plates, bearings or spacers. In some embodiments, the one or more first guide wheels run on the one or more rail profiles 104A-N and 106A-N of the storage facility 100.
[0064] The second drive assembly 214 is mounted on at least one of the top supporting frame 208 to operate the work handling platform 202 on the one or more pillars 206A-N of the structured frame. The second drive assembly 214 includes a second driving motor and at least one of a ball screw rod assembly or a pulley assembly. The ball screw rod assembly or the pulley assembly is coupled with the work handling platform 202 to operate the work handling platform 202 on the one or more pillars 206A-N. The second drive assembly 214 is mounted on the top supporting platform 208 using at least one of the one or more cover plates or the one or more spacers. The second drive assembly 214 is mounted with at least one of the ball screw rod assembly or the pulley assembly using at least one of the gear assembly, the one or more bearings, the one or more spacers or the one or more cover plates. In some embodiments, the second drive assembly 214 is mounted with at least one of the ball screw rod assembly or the pulley assembly using one or more flanges.
[0065] The work handling platform 202 includes one or more plates 216A-N, an object picker 218 and a guide wheel assembly 220. The one or more plates 216A-N are mounted together to form housing. In some embodiments, the housing accommodates at least one of a work handling platform drive assembly, control assemblies, sensors or communicating device. In some embodiments, the work handling platform 202 handles the objects at a middle portion of the housing. In some embodiments, the object picker 218 handles the objects on the work handling platform 202. The object picker 218 includes at least one of an arm assembly or a moving cart to handle the objects. The work handling platform 202 is mounted on the automatic storage and retrieval machine 116 handles the objects on the one or more storage rows 124A-N that are located on each side of the aisle row 126 of the storage facility 100. The guide wheel assembly 220 is mounted on each side of the housing to guide the work handling platform 202 on the one or more pillars 206A-N when the work handling platform 202 is operated by the second drive assembly 214. The second drive assembly 214 is coupled with the work handling platform 202 using at least one of the belts or chain of the second driving assembly 214 using one or more holding plates mounted on each side of the housing.
[0066] FIG. 2B illustrates an exemplary view of the automated storage and retrieval machine 116 with a ball screw rod assembly 222 according to some embodiments herein. The ball screw rod assembly 222 is coupled with at least one of the top supporting frame 208 and the base frame 204. In some embodiments, the wheel support frames are mounted on the at least one of the top supporting frame 208 and the base frame 204 to couple the ball screw rod assembly 222. The ball screw rod assembly 222 is mounted with the work handling platform 202 using one or more linear guideways. In some embodiments, the ball screw rod assembly 222 is driven by the second drive assembly 214. The work handling platform 202 is operated up and down direction on a pair of ball screw rods and the one or more linear guideways. In some embodiments, the pair of ball screw rods are mounted between the top supporting frame 208 and the base frame 204. In some embodiments, the ball screw rod assembly 222 drives the work handling platform 202 at least one of simultaneously or sequentially on the one or more aisle rows 126A-N or on the automated storage and retrieval machine 116.
[0067] FIG. 2C illustrates an exemplary view of the automated storage and retrieval machine 116 with a pulley assembly 224 according to some embodiments herein. The pulley assembly 224 includes one or more pulleys. In some embodiments, a two pair of pulleys that are mounted on at least one of the top supporting frame 208 or the base frame 204. Each pair of pulleys is coupled with a shaft using at least one of flanges, bearings or housing plates. The pulley assembly 224 mounted on the top supporting frame 208 and the pulley assembly 224 mounted on the base frame 204 are coupled using at least one of chain or belt. The pulley assembly 224 is coupled with the work handling platform 202 using one or more holding plates mounted on each side of the housing of the work handling platform 202. In some embodiments, the pulley assembly 224 drives the work handling platform 202 at least one of simultaneously or sequentially on the one or more aisle rows 126A-N or on the automated storage and retrieval machine 116.
[0068] FIG. 3A illustrates an exemplary view of the automated storage and retrieval machine 116 with an arm assembly 302 according to some embodiments herein. The arm assembly 302 includes one or more supporting plates, one or more supporting tubes, a pair of arm plate assembly and a driving assembly. The one or more supporting plates and the one or more supporting tubes that form a housing. The pair of arm plate assembly is mounted on a middle portion of the housing. The arm plate assembly includes at least one of (a) a base plate that is mounted on a housing platform, (b) one or more middle plates are coupled with the base plate using one or more sliding assembly or (c) an end plate that is coupled with the at least one of the middle plate using the one or more sliding assembly. The end plate is coupled with one or more fingers to handle the objects on the storage facility 100. The driving assembly is mounted on at least one end portion of the housing to drive the pair of arm plate assembly using at least one of the sliding assembly mounted on the pair of arm plate assembly, a driving motor, a gear assembly, a drive shaft, chains or belts. The arm assembly is at least one of (a) moved simultaneously or (b) moved sequentially on the one or more aisle rows 126A-N or on the automated storage and retrieval machine 116.
[0069] FIG. 3B illustrates an exemplary view of the automated storage and retrieval machine 116 with a moving cart 304 according to some embodiments herein. The moving cart includes a lifting platform, one or more driving wheels, one or more non-driving wheels, one or more guide wheels or a moving cart drive assembly. The work handling platform 202 includes a rail for the moving cart 304 on a middle portion of the work handling platform 202. In some embodiments, the one or more three-dimensional rack assembly 102A-N includes one or more rails on the one or more storage rows 124A-N for the moving cart 304. The moving cart drive assembly drives the moving cart 304 between the work handling platform 202 and the one or more storage rows 124A-N to handle the objects. In some embodiments, the moving cart 304 handles the objects between at least one of the one or more storage rows 124A-N, the one or more object transfer rows 128A-N or the automated storage and retrieval machine 116. The moving cart 304 is at least one of (a) moved simultaneously or (b) moved sequentially on the one or more aisle rows 126A-N or on the automated storage and retrieval machine 116.
[0070] With reference to the FIGS. 1A to 3B, FIG. 4 is a flow diagram of a method of storing and retrieving objects on the storage facility 100 using one or more automated storage and retrieval machines 116A-N of FIG. 1 according to some embodiments herein. At step 402, the objects are placed on the one or more object handling positions on the one or more object transfer rows 128A-N of the storage facility 100 using the one or more conveyors. At step 404, the one or more automated storage and retrieval machines 116A-N are moved on the one or more aisle rows 126A-N between at least one of the one or more storage positions or the one or more object handling positions using the one or more rail profiles 104A-N and 106A-N. At step 406, the objects are placed on the work handling platform 202 of the one or more automated storage and retrieval machines 116A-N from at least one the one or more storage position or the one or more object handling position using an object picker 218 of the one or more automated storage and retrieval machines 116A-N. At step 408, the objects are moved to at least one of the one or more storage positions or the one or more object handling positions associated with at least one of the one or more aisle rows 126A-N or the one or more object transfer rows 128A-N using the one or more automated storage and retrieval machines 116A-N. At step 410, the objects are placed on at least one of the one or more storage positions or the one or more object handling position from the one or more automated storage and retrieval machines 116A-N using the work handling platform 202. When in operation, the object is at least one of (a) moved simultaneously or (b) moved sequentially on the one or more aisle rows 126A-N or the one or more automated storage and retrieval machines 116A-N.
[0071] In some embodiments, the automated storage and retrieval machine 116 stores the object to a storage position on the storage facility 100 includes (a) placing the objects on an object handling position on an object transfer row 126 of the storage facility 100 using the one or more conveyors, (b) moving the automated storage and retrieval machine 116 to the object transfer row 128 that is associated with the object handling position using the one or more rail profiles 104A-N and 106A-N, (c) placing the object on the work handling platform 202 from the object handling position using the object picker 218 of the work handling platform 202, (d) moving the object on at least one of (i) the aisle row 126 on the one or more rail profiles 104A-N and 106A-N to the storage position using the automated storage and retrieval machine 116 or (ii) the automated storage and retrieval machine 116 to a storage row level of the storage facility 100 that is associated with the storage position using the work handling platform 202 and (e) placing the object on the storage position by removing the object from the automated storage and retrieval machine 116 using the object picker 218 of the automated storage and retrieval machine 116.
[0072] In some embodiments, the automated storage and retrieval machine 116 retrieves the object to a storage position on the storage facility 100 includes (a) moving the automated storage and retrieval machine 116 to a storage row level that is associated with the storage position using the one or more rail profiles 104A-N and 106A-N of the storage facility 100, (b) placing the object on the work handling platform 202 by removing the object from the storage position using the object picker 218 of the automated storage and retrieval machine 116, (c) moving the object on at least one (i) the aisle row 126 on the one or more rail profiles 104A-N and 106A-N to the object transfer row 128 associated with an object handling position, or (ii) the automated storage and retrieval machine 116 to the object handling position using the work handling platform 202 and (d) placing the object on the object handling position by removing the object from the automated storage and retrieval machine 116 using the object picker 218 of the automated storage and retrieval machine 116.
[0073] In some embodiments, the automated storage and retrieval system stores and retrieves the objects on the storage facility 100 using the one or more automated storage and retrieval machines 116 by (a) placing the objects on a lift assembly using the one or more conveyors and (b) moving the objects between the object handling position that is associated with a desired storage row level and the conveyor assembly of the storage facility 100 using the lift assembly. The storage facility 100 is mounted with at least one automatic storage and retrieval machine for each (a) at least five storage row levels and (b) aisle row of the storage facility.
[0074] In some embodiments, the objects are encoded by the centralized computing device. In some embodiments, the centralized computing device determines a location and a level for an encoded object in the storage facility 100. In some embodiments, the encoded object is conveyed to where the object handling position is placed. In some embodiments, the automated storage and retrieval machine 116 receives details associated with the location and the level of the encoded object from the centralized computing device.
, Claims:We Claim:
1. A system for storing and retrieving objects in automated storage and retrieval system comprising,
a storage facility (100) that comprises a plurality of rail profiles (104A-N and 106A-N) on a plurality of aisle rows (126A-N) at a defined distance, wherein the plurality of rail profiles (104A-N and 106A-N) is mounted on a plurality of structured uprights (108A-N) of at least one side of the aisle row (126) of the storage facility (100);
a plurality of automated storage and retrieval machines (116A-N) that is mounted on the plurality of rail profiles (104A-N and 106A-N), wherein the plurality of automated storage and retrieval machines (116A-N) run on the plurality of rail profiles (104A-N and 106A-N) and handles objects between a plurality of storage positions and a plurality of object handling positions of the storage facility (100),
wherein when in operation, the system operates the automated storage and retrieval machine (116) to handle the objects between a defined storage rows (124) and a defined object transfer rows (128) on the aisle row (126), wherein the automated storage and retrieval machine (116) comprises a work handling platform (202) that is operated to handle the objects at a defined storage rows (124A-N) of the storage facility (100).

2. The system as claimed in claim 1, wherein the storage facility (100) comprises
a plurality of storage rows (124A-N) that provides the plurality of storage positions for the objects, wherein the plurality of storage rows (124A-N) is formed by mounting a plurality of deck structures (112A-N) between at least two structured beams (110A and 110B) that are mounted parallelly with a plurality of structured uprights (108A-N), wherein the plurality of storage rows (124A-N) forms a three-dimensional rack;
the plurality of aisle rows (126A-N) that provides a runway for the plurality of automatic storage and retrieval machines (116A-N), wherein the plurality of aisle rows (126A-N) is formed between the at least two three-dimensional rack assembly (102A and 102B) that are positioned parallelly;
the plurality of object transfer rows (128A-N) that provides a plurality of object handling positions for the automated storage and retrieval machine (116); and
a plurality of stopper profiles (130A-N) that are mounted on a plurality of structured beams (110A-N) that are mounted outside of the three-dimensional rack assembly (102).

3. The system as claimed in claim 1, wherein the automated storage and retrieval machine (116) comprises
the work handling platform (202) that is mounted on a structured frame of the automated storage and retrieval machine (116), wherein the work handling platform (202) runs on the structured frame to handle the objects between at least one of the defined storage row levels and the plurality of object handling positions, wherein the structured frame comprises at least one of a base frame (204), a plurality of pillars (206A-N), a top supporting frame (208) or a control panel frame (210);
a first drive assembly (212) that is mounted on the top supporting frame (208) to operate the automated storage and retrieval machine (116) on the plurality of rail profiles (104A-N and 106A-N); and
a second drive assembly (214) that is mounted on at least one of the top supporting frame (208) to operate the work handling platform (202) on the plurality of pillars (206A-N) of the structured frame.

4. The system as claimed in claim 1, wherein the first drive assembly (212) comprises
a plurality of first wheels that is mounted on at least one of the top supporting frame (208) or the plurality of pillars (206A-N) using at least one of a plurality of mounting plates, bearings or spacers, wherein the plurality of first wheels run on the plurality of rail profiles (104A-N and 106A-N) of the storage facility (100);
a first driving motor that is coupled with the at least one first wheel using at least one of the mounting plates, gear assembly, a drive shaft, bearing or spacers; and
a plurality of first guide wheels that is mounted on at least one of the top supporting frame (208) or the plurality of pillars (206A-N) using at least one of a plurality of mounting plates, bearings or spacers, wherein the plurality of first guide wheels run on the plurality of rail profiles (104A-N and 106A-N) of the storage facility (100).

5. The system as claimed in claim 1, wherein the second drive assembly (214) comprises
at least one of a ball screw rod assembly (222) or a pulley assembly (224) that is coupled with the work handling platform (202) to operate the work handling platform (202) on the one or more pillars (206A-N); and
a second driving motor that is mounted on the top supporting frame (208) and coupled with at least one of the ball screw rod assembly (222) or the pulley assembly (224) using at least one of the mounting plates, gear assembly, a drive shaft, bearing or spacers.

6. The system as claimed in claim 1, wherein the work handling platform (202) comprises
a plurality of plates (216A-N) that forms a housing;
an object picker (218) that handles the objects, wherein the object picker (128) comprises
an arm assembly (302) that is mounted on a middle portion of the housing, wherein the arm assembly (302) handles the objects on at least one of the plurality of storage rows (124A-N), the plurality of object transfer rows (128A-N) or the automated storage and retrieval machine (116); or
a moving cart (304) that handles the objects between at least one of the plurality of storage rows (124A-N), a plurality of object transfer rows (128A-N) or the automated storage and retrieval machine (116); and
a guide wheel assembly (220) that is mounted on each side of the housing to guide the work handling platform (202) on the plurality of pillars (206A-N) when the work handling platform (202) is operated by the second drive assembly (214), wherein the second drive assembly (214) is coupled with the work handling platform (202) using at least one of the belt or chain of the second driving assembly (214) using a plurality of holding plates mounted on each side of the housing.

7. The system as claimed in claim 1, wherein the object picker (218) is mounted on the housing of the work handling platform (202), wherein the object picker (218) comprises an arm assembly (302) that comprises
a plurality of supporting plates and a plurality of supporting tubes that form a housing;
a pair of arm plate assembly that are mounted on a middle portion of the housing, wherein the arm plate assembly comprises at least one of (a) base plate that is mounted on the housing platform, (b) a plurality of middle plates that are coupled with the base plate using a plurality of sliding assembly or (c) an end plate that is coupled with the at least one of the middle plate using the plurality of sliding assembly, wherein the end plate is coupled with a plurality of fingers to handle the objects on the storage facility; and
a driving assembly that is mounted on at least one end portion of the housing to drive the pair of arm plate assembly using at least one of the sliding assembly mounted on the pair of arm plate assembly, a driving motor, a gear assembly, a drive shaft, chains or belts, wherein the arm assembly (302) is at least one of (a) moved simultaneously or (b) moved sequentially on the plurality of aisle rows (126A-N) or on the automated storage and retrieval machine (116).

8. The system as claimed in claim 1, wherein the object picker (218) of the object picker (218) comprises a moving cart (304) that handles the objects between at least one of the plurality of storage rows (124A-N), a plurality of object transfer rows (128A-N) or the automated storage and retrieval machine (116), wherein the moving cart (304) is at least one of (a) moved simultaneously or (b) moved sequentially on the plurality of aisle rows (126A-N) or on the automated storage and retrieval machine (116).

9. The system as claimed in claim 1, wherein the work handling platform (202) mounted on the automatic storage and retrieval machine (116) handles the objects on the plurality of storage rows (124A-N) that is located on each side of the aisle row (126) of the storage facility (100).

10. The system as claimed in claim 1, wherein the plurality of storage rows (124A-N) that are formed vertically on the plurality of structured uprights (108A-N) to form a plurality of storage row levels, wherein the plurality of storage rows (124A-N) and the plurality of aisle rows (126A-N) are mounted in traverse on the storage facility (100).

11. The system as claimed in claim 1, wherein the system comprises at least one automatic storage and retrieval machine (116) for each (a) at least five storage row levels and (b) aisle row (126) of the storage facility (100).