DESC:BACKGROUND
Technical Field
[0001] The embodiments herein generally relate to warehouse storage devices, more particularly to a device and a method for transferring object containers in storage lanes automatically.
Description of the Related Art
[0002] For instance, computer-controlled systems for automatically storing (placing) and recovering objects from predetermined storage locations are included in automated storage and retrieval systems (AS/RS). Totes (or bins), the smallest unit of load for the system, are frequently used in traditional AS/RS. Dairies and warehouse storage facilities, for instance, may use traditional AS/RS. In these systems, the totes are delivered to users who access the totes' contents. The tote is then re-inducted back into the AS/RS after a user has finished using it. In these systems, items are kept in containers that are kept in storage lanes by stacker cranes, shuttles, or both. To reach each level of the storage lane, stacker cranes are moved between aisles of the storage lane. The amount of time and resources needed to transport totes toward and then away from each container access point is a limitation of such conventional systems, though.
[0003] In recent days, shuttles are introduced to run between each aisle of the storage lane to access the containers that are stored in the levels of the storage lane. The shuttles are made with a hard metal that provides a housing to accommodate at least one of a driving assembly, a conveying assembly or supporting electrical or electronic components. The manufacturing process and structure design of the shuttles are complex in existing solutions. There remains a need for devices in a simple manufacturing process, working process and structure design to access the containers in the storage lane.
[0004] Accordingly, there remains a need for a device and a method for transferring object containers in storage lanes automatically.

SUMMARY
[0005] Embodiments herein provide an object container transport device for transporting object containers in a storage lane automatically. The object container transport device includes one or more brackets, a driving assembly, a work handling assembly and a base frame assembly. The driving assembly is connected to a control unit and drives the object container transport device based on comments received from the control unit. The driving assembly includes a pair of driving wheels and a pair of non-driving wheels. The work handling assembly handles at least one object containers using at least one of a conveyor assembly or a fork assembly based on the comments received from the control unit. The base frame assembly includes one or more sheet metal profiles are arranged to form a housing to accommodate at least one of the driving assembly, the work handling assembly or the control unit. The base frame assembly includes one or more openings and mounts at least one of a driving assembly, a guide wheel assembly, the fork assembly, the conveyor assembly or the control unit using the one or more brackets.
[0006] In some embodiments, the base frame assembly includes a pair of housing, one or more power pins, one or more sheet metal tube structures. The pair of housing on both end portion of the base frame assembly that accommodate at least one of the control unit, a communication unit, a power unit, one or more sensors, one or more relays, one or more actuators, one or more switches or one or more indicators. The one or more power pins are mounted on at least one side portion of the base frame assembly. The one or more sheet metal tube structures are mounted with the base frame assembly to increase a load carrying capacity. A middle portion of the base frame assembly is mounted with the work handling assembly.
[0007] In some embodiments, the driving assembly includes the pair of driving wheels, the pair of non-driving wheels, a driving motor a driving shaft and a sheet metal support frame. The pair of driving wheels and the pair of non-driving wheels. The driving wheels are mounted on the base frame assembly using the one or more brackets. The driving motor is coupled with the pair of driving wheels to drive the object container transport device on a rail of the storage lane. The driving motor is coupled with the pair of driving wheels using a driving shaft. The driving shaft is coupled with the driving motor and the pair of driving wheels using at least one a driving gear assembly or one or more driving bearings. The sheet metal support frame provides the support for the driving shaft.
[0008] In some embodiments, the work handling assembly is mounted on the middle support of the base frame assembly using the one or more brackets. The work handling assembly includes a fork assembly that includes a pair of arms that are driven by at least one of a fork motor, a fork drive shaft, one or more timing belts, pulleys or one or more guide wheels. The one or more guide wheels are coupled with a belt and run on a side plates of the fork assembly.
[0009] In some embodiments, the side plates of the work handling assembly are mount with the base frame assembly using at least one stiffener.
[0010] In some embodiments, the one or more brackets are single sheet metal bending structures that include a front portion, at least one side portion and a bottom portion. The front portion includes one or more openings to mount at least one of the driving assembly or the work handling assembly. The at least one side portion includes a structured stiffener. The bottom portion is mounted on the base frame assembly. The bottom portion is joint with the at least one side portion by at least one of welding or fastening.
[0011] In some embodiments, the one or more brackets are structured single sheet metal brackets that include a wheel bracket that is mounted on at least one corner of the base frame assembly by at least one of welding or fastening to mount at least one of the driving wheels, the non-driving wheels or guide wheels.
[0012] In some embodiments, the one or more brackets are the structured single sheet metal brackets that includes a fork brackets that is mount with side plates of the work handling assembly and the base frame assembly by at least one welding or fastening.
[0013] In another aspect, a method of storing and retrieving objects containers in a storage lane using a device includes (a) encoding, using a centralized management system, the object containers, (b) determining, using the centralized management system, a location details of at least one encoded object container in the storage lane for at least one of storage or retrieval operation, (c) communicating the location details of the encoded object container from the centralized management system to the object container transport device, (d) determining the location for the encoded object container by scanning a plurality of embedded codes on the storage lane and (e) enable at least one of storage or retrieval operation at a location where the plurality of embedded codes is matched with the location details of the encoded object container received from the centralized management system.
[0014] In some embodiments, the method includes conveying the at least one encoded object container to a level of the storage lane where the device is placed when performing at least one of the storage or the retrieval operation.
[0015] In some embodiments, the operation is reversed for retrieval of the object container from the storage rack. In some embodiments, the proposed structural design is smaller than any commercial designs. In some embodiments, the device 100 manufacturing process is simple as made with the sheet metal. The cost of the device 100 is 25% to 50% less than any commercial device. In some embodiments, the speed of the device 100 is between 1 meter/ second to 5 meter/ sec. The payload of the device 100 is in the range of 10 kilograms to 80 kilograms. The device 100 can handle the objects containers in the size ranges from 100*100 millimetre to 900*900 millimetre.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
[0017] FIG. 1 illustrates an exemplary diagram of an object container transport device for transporting object containers in a storage rack according to some embodiments herein;
[0018] FIG. 1B illustrates an exemplary view of a base frame assembly of an object container transport device according to some embodiments herein; and
[0019] FIG. 3 is a flow diagram of a method of storing and retrieving objects containers using an object container transport device of FIG. 1 according to some embodiments herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] 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.
[0021] An objective of the current invention is to provide a device and method for transferring object containers in storage lanes automatically in an automatic storage and retrieval system 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. 3, where similar reference characters denote corresponding features consistently throughout the figures, preferred embodiments are shown.
[0022] FIG. 1 illustrates an exemplary diagram of the object container transport device 100 for transporting object containers in a storage rack according to some embodiments herein. The object container transport device 100 includes a base frame assembly 102, a driving assembly 104, a work handling assembly 106, one or more brackets 108A-N. The base frame assembly 102 includes one or more sheet metal profiles. In some embodiments, the one or more sheet metal profiles forms a pair of housings 110A and 110B on both ends of the base frame assembly 102. In some embodiments, the pair of housings 110A and 110B accommodates at least one of a control unit, a communication unit, a power unit, one or more sensors, one or more relays, one or more actuators, one or more switches or one or more indicators. In some embodiments, the storage racks include conductor rails that provide the power supply to the object container transport device 100 using the power supply components. The base frame assembly 102 includes at least one power pin (for example: current collectors). In some embodiments, the object container transport device 100 collects the power from a power bus installed on a rail of the storage rack using the power pins. One or more sheet metal tube structures 124A-N are mounted on the base frame assembly 102 to increase at least one of strength, stability and load-carrying capacity. The middle portion of the base frame assembly 102 mounts the work handling assembly 106. In some embodiments, the one or more brackets 108A-N are mounted on the base frame assembly 102. In some embodiments, the base frame assembly 102 includes one or more openings for reducing the weight of the object container transport device 100. The work handling assembly 106 includes at least one of a conveyor assembly or a fork assembly. In some embodiments, the work handling assembly 106 is made with the sheet metal. The work handling assembly 106 is mounted on the base frame assembly 102 and accommodates at least one of the conveyor assembly or the fork assembly which handles object containers.
[0023] The one or more brackets 108A-N include a wheel bracket and a fork bracket. The one or more brackets are single sheet metal bending structures. The one or more brackets 108A-N include a front portion, a side portion and a bottom portion. The front portion 126 includes one or more openings to mount at least one of the driving assembly or the work handling assembly. In some embodiments, the one or more brackets 108A-N include at least one side portion 128 that includes a structured stiffener. The bottom portion 130 is mounted on the base frame assembly 102. The bottom portion is joined with the at least one side portion by at least one of welding or fastening.
[0024] The driving assembly 104 includes a pair of driving wheels 112A and 112B, a pair of non-driving wheels 114A and 114B, a driving motor 116, a driving shaft 118, one or more guide wheels 120A-N and a sheet metal support frame 122. The pair of driving wheels 112A-N are mounted on the base frame assembly 102 using at least one wheel bracket and wheel bearings. Both ends of the driving shaft 118 is coupled with the pair of driving wheels 112A and 112B using the wheel bearings. The driving shaft 118 is coupled with the driving motor 116 using the sheet metal support frame 122 and a driving gear assembly. In some embodiments, the sheet metal support frame 122 is coupled with the one or more sheet metal profiles of the base frame assembly 102. The one or more guide wheels 120A-N are mounted on the base frame assembly 102 using one or more guide roller plates. In some embodiments, the guide roller plates and the one or more sheet metal profiles are mounted on the base frame assembly 102 using one or more wheel support plates.
[0025] The one or more brackets 108A-N are structured single sheet metal brackets that include a wheel bracket that is mounted on at least one corner of the base frame assembly 102 by at least one of welding or fastening to mount at least one of the pair of driving wheels 112A and 112B, the pair of non-driving wheels 114A and 114 B or the one or more guide wheels 120A-N. The fork bracket is mounted on side plates of the work handling assembly 106 and the base frame assembly 102 by at least one of welding or fastening. In some embodiments, the one or more brackets 108A-N are made with the sheet metal.
[0026] In some embodiments, when the work handling assembly 106 is the conveyor assembly that includes a conveyor motor, a conveyor drive shaft, a conveyor belt or a conveyor gear assembly. In some embodiments, when the work handling assembly 106 is the fork assembly that includes a pair of arms that are driven by at least one of a fork motor, a fork drive shaft, one or more timing belts, pulleys or one or more fork assembly guide wheels. The one or more fork assembly guide wheels are coupled with a belt and run on the side plates of work handling assembly 106. The side plates of the work handling assembly 106 are mounted with the base frame assembly 102 using at least one stiffener 122A-N. In some embodiments, the stiffeners 122A-N are sheet metal profiles that are mounted on the base frame assembly 102 using at least one of welding or fastening.
[0027] In some embodiments, the object container transport device 100 is provided for each level of the storage racks. The storage racks include rails at each level to provide a platform for the object container transport device 100. In some embodiments, the rails are channel-structured profiles. The object container transport device 100 runs on the rails using the driving assembly 104 based on comments provided by the control unit. In some embodiments, the control unit is communicatively connected with a centralized management system (for example: warehouse management system (WMS)). In some embodiments, the one or more guide wheels 120A-N are mounted inside the rails and one or more brackets 108A-N for providing high stability and precision start and stop. In some embodiments, the control unit is installed on the object container transport device 100 to control the operations remotely.
[0028] With reference to the FIG. 1, FIG. 1B illustrates an exemplary view of the base frame assembly 102 of the object container transport device 100 according to some embodiments herein. The base frame assembly 102 includes the pair of driving wheels 112A and 112B, the pair of non-driving wheels 114A and 114B, a drive shaft 118, one or more wheel brackets 132A-N, a power pin 134, a gear assembly 136, one or more fork brackets 138A-N and one or more buffers 140A-N. The one or more wheel brackets 132A-N are mounted on corners of the base frame assembly 102. The one or more wheel brackets 132A-N are accommodating at least one bearing to carry the load. The bearings are mounted with the one or more wheels 112A, 112B, 114A and 114B. The one or more wheel brackets 132A-N accommodate the one or more guide wheels 120A-N. The one or more fork brackets 138A-N are configured to mount at least one fork assembly for handling the object containers.
[0029] In some embodiments, the drive shaft 118 connects the pair of driving wheels 112A and 112B and drives using the gear assembly 136. In some embodiments, the gear assembly 136 is driven by the driving motor 116 based on the control signals provided by the centralized management system. In some embodiments, the base frame assembly 102 provides the housing 110A and 110B for at least one of motors, readers, scanners, Programmable logic controllers (PLCs), communication devices, busses, relays or switches. In some embodiments, the base frame assembly 102 includes one or more openings that reduce the weight. The one or more buffers 140A-N are mounted at the outer edge of the object container transport device 100 to avoid physical damage during start and stop.
[0030] With reference to the FIGS. 1 and 2, FIG. 3 is a flow diagram of a method of storing and retrieving object containers using the object container transport device 100 of FIG. 1 according to some embodiments herein. At step 302, object containers are encoded by the centralized management system. At step 304, The centralized management system determines location details of at least one encoded object container in the storage lane for at least one of storage or retrieval operation. At step 306, the location details of the encoded object container are communicated from the centralized management system to the object container transport device 100. At step 308, the object container transport device 100 determines the location for the encoded object container by scanning a plurality of embedded codes on the storage lane. At step 310, at least one of storage or retrieval operation is enabled at a location where the plurality of embedded codes is matched with the location details of the encoded object container received from the centralized management system. In some embodiments, the at least one encoded object container is conveyed to a level of the storage lane where the device is placed when performing a storage operation.
[0031] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.
,CLAIMS:We Claim:
1. An object container transport device (100) for transporting object containers in a storage lane automatically comprising,
a plurality of brackets (108A-N);
a driving assembly (104) that is connected to a control unit and drives the object container transport device (100) based on comments received from the control unit, wherein the driving assembly (104) comprises a pair of driving wheels (112A and 112B) and a pair of non-driving wheels (114A and 114B);
a work handling assembly (106) that handles at least one object container using at least one of a conveyor assembly or a fork assembly based on the comments received from the control unit; and
a base frame assembly (102) that comprises a plurality of sheet metal profiles that are arranged to form a housing (110A and 110B) to accommodate at least one of the driving assembly (104), the work handling assembly (106) or the control unit, wherein the base frame assembly (102) comprises a plurality of openings and mount the at least one of a driving assembly (104), a guide wheel assembly, the fork assembly, the conveyor assembly or the control unit using the plurality of brackets (108A-N).

2. The object container transport device (100) as claimed in claim 1, the base frame assembly (102) comprises
a pair of housings (110A and 110B) on both end portions of the base frame assembly (102) that accommodate at least one of the control unit, a communication unit, a power unit, a plurality of sensors, a plurality of relays, a plurality of actuators, a plurality of switches or a plurality of indicators;
a plurality of power pins (134) that are mounted on at least one side portion of the base frame assembly (102); and
a plurality of sheet metal tube structures (124A-) that are mounted with the base frame assembly (102) to increase a load-carrying capacity, wherein a middle portion of the base frame assembly (102) is mounted with the work handling assembly (106).

3. The object container transport device (100) as claimed in claim 1, wherein the driving assembly (104) comprises
the pair of driving wheels (112A and 112B) and the pair of non-driving wheels (114A and 114B), wherein the pair of driving wheels (112A and 112B) and the pair of non-driving wheels (114A and 114B) are mount on the base frame assembly (102) using the plurality of brackets (108A-N);
a driving motor (116) that is coupled with the pair of driving wheels (112A and 112B) to drive the object container transport device (100) on a rail of the storage lane, wherein the driving motor (116) is coupled with the pair of driving wheels (112A and 112B) using a driving shaft (118);
the driving shaft (118) is coupled with the driving motor (116) and the pair of driving wheels (112A and 112B) using at least one of a driving gear assembly or a plurality of driving bearings; and
a sheet metal support frame (112) that provides the support for the driving shaft (118).

4. The object container transport device (100) as claimed in claim 1, wherein the work handling assembly (106) is mounted on the middle support of the base frame assembly (102) using the plurality of brackets (108A-N), wherein the work handling assembly (106) comprises a fork assembly that comprises a pair of arms that are driven by at least one of a fork motor, a fork drive shaft, a plurality of timing belts, pulleys or a plurality of guide wheels, wherein the plurality of fork assembly guide wheels are coupled with a belt and run on a side plate of the work handling assembly (106).

5. The object container transport device (100) as claimed in claim 4, wherein the side plates of the work handling assembly (106) are mounted with the base frame assembly (102) using at least one stiffener.

6. The object container transport device (100) as claimed in claim 1, wherein the plurality of brackets (108A-N) are single sheet metal bending structures that comprises
a front portion (126) that comprises a plurality of openings to mount at least one of the driving assembly (104) or the work handling assembly (106);
at least one side portion (128) that comprises a structured stiffener; and
a bottom portion (130) that is mounted on the base frame assembly, wherein the bottom portion is joined with the at least one side portion (128) by at least one of welding or fastening.

7. The object container transport device (100) as claimed in claim 1, wherein the plurality of brackets (108A-N) are structured single sheet metal brackets that comprise wheel brackets (132A-N) that are mounted on at least one corner of the base frame assembly (102) by at least one of welding or fastening to mount at least one of the driving wheels (112A and 112B), the non-driving wheels (114A and 114B) or guide wheels (12A-N).

8. The object container transport device (100) as claimed in claim 1, wherein the plurality of brackets (108A-N) is the structured single sheet metal brackets that comprise fork brackets (138A-N) that are mounted with side plates of the work handling assembly (106) and the base frame assembly (102) by at least one welding or fastening.

9. A method of storing and retrieving objects containers in a storage lane using an object container transport device (100) comprising
encoding, using a centralized management system, the object containers;
determining, using the centralized management system, location details of at least one encoded object container in the storage lane for at least one of storage or retrieval operation;
communicating the location details of the encoded object container from the centralized management system to the object container transport device (100);
determining the location for the encoded object container by scanning a plurality of embedded codes on the storage lane; and
enable at least one of storage or retrieval operation at a location where the plurality of embedded codes is matched with the location details of the encoded object container received from the centralized management system.

10. The method as claimed in claim 8, wherein the method comprises conveying the at least one encoded object container to a level of the storage lane where the object container transport device (100) is placed when performing at least one of the storage or the retrieval operation.