DESC:BACKGROUND
Technical Field
[0001] The embodiments herein generally relate to a transport device, more particularly to a device and a method for transporting an object carrier between different channels of storage racks.
Description of the Related Art
[0002] Automatic storage and retrieval systems are widely used in different industries where the storage and retrieval of goods is large. Storage and shipping of goods is a process that is carried out in many ways for many purposes. Manufacturers generally store and deliver pallets containing product cases within the manufacturer's distribution facility to fulfill orders for products. The pallets are retrieved and stored on storage racks using machines such as stacker cranes, shuttles, forklifts, reach trucks, etc. Machines like stacker cranes, forklifts and reach trucks are able to store or retrieve the pallets by moving through the aisles of the storage racks. In addition, such machines regularly require additional space for maneuvering, so their use leads to a reduction in the available storage capacity. There remains a need for a system or a device to reduce the space utilization of the storage rack and multi-deep storing and retrieving. The machines such as shuttles have overcome that problem. The shuttles are able to travel deep into each level in a row and perform the storage and retrieval operations. The commercially used shuttles are designed to travel in a single row of storage racks and shuttles have to be placed for each row of storage racks to access the objects which is an expensive and complex process. There remains a need for a device or a method to transport the shuttles between the rows of the storage racks. The commercially available solutions for transporting the shuttles between the rows are conveyors, carriers, or special shuttles that can move in both directions. The conveyors are simple and occupy more space and components which leads to expense. The special shuttles are complex in design and include more components which leads to expense. The carriers are commercially used methods for transporting the shuttles between the rows as the carriers are simple in design and cheaper than the conveyors and the special shuttles.
[0003] However, commercial carriers are regularly slow and limited in terms of storage depth. The technical problem of the present invention is to increase the flexibility and throughput of a storage system.
[0004] Accordingly, there remains a need for a device and a method of transporting an object carrier between different channels of storage racks.

SUMMARY
[0005] Embodiments herein provide an object carrier transport device for automatic storage and retrieval to transport an object carrier between channels of storage racks at an instance. The device includes an object carrier, a driving assembly, an object conveyor assembly and an object carrier base frame assembly. The object carrier is transported between one or more channels of a storage rack. The one or more channels include a channel rail for the object carrier. In some embodiments, the object carrier includes an object carrier frame, an object carrier driving assembly or an object carrier lifting assembly. The driving assembly drives the object carrier transport device on one or more aisles of the storage rack and each aisle includes an object carrier transport device rail. The object conveyor assembly conveys objects between the object carrier transport device to a transport conveyor. The object carrier base frame assembly accommodates (i) the driving assembly or (ii) the object conveyor assembly. In some embodiments, the object carrier base frame assembly includes one or more tensioner adjustment plates that are coupled with one or more chain tensioner rollers for adjusting tension on at least one of the driving assembly or the object conveyor assembly.
[0006] In some embodiments, the object carrier includes the object carrier frame that accommodates (i) one or more sensors, (ii) one or more switches, (iii) the object carrier driving assembly or (iv) the object carrier lifting assembly. The object carrier driving assembly drives the object carrier on the channel rail. In some embodiments, the object carrier driving assembly includes one or more driving wheels and one or more guiding wheels. The one or more driving wheels coupled with a driving motor using at least one of a first gearbox, a first drive chain and a first drive shaft. The object carrier lifting assembly lifts up the object carrier. In some embodiment, In some embodiments, the object carrier lifting assembly includes a lifting motor is coupled with a lifting gear using a chain sprocket, a pair of lift cams coupled with each end of a lift shaft using a plumber block and at least two pairs of lifting blocks are coupled with the lift cam to lift up and lift down the object when performing (i) storing or (ii) retrieving operation. Each pair of lifting blocks are coupled with a pair of liver plate and a liner plate for synchronous operation.
[0007] In some embodiments, the driving assembly includes a driving motor, one or more driving wheels and one or more guide wheels. The driving motor is coupled with a driving shaft using a driving gear assembly. The one or more driving wheels are coupled with the driving shaft using one or more sprockets. The one or more guide wheels are on the object carrier base frame to guide the object carrier transport device on the object carrier transport device rail.
[0008] In some embodiments, the storage rack includes one or more aisles and one or more channels. The one or more aisles include one or more object carrier transport device rail on each level of the aisle for the object carrier transport device. The channels at each level of the storage rack include one or more channel rails for the object carrier.
[0009] In some embodiments, the object conveyor assembly includes a conveyor motor, the conveyor drive shaft and a chain. The conveyor motor (318) is coupled with a conveyor drive shaft. The conveyor drive shaft is coupled with a pair of conveyor sprockets using a pair of flange bearings. The chain is coupled with the chain sprocket and a tension sprocket.
[0010] In some embodiments, the object carrier base frame assembly includes an object carrier platform for the object carrier.
[0011] The proposed device addresses the shortcomings of existing systems and offers a more efficient and cost-effective solution for automatic storage and retrieval in various industries. Additionally, the object carrier transport device provides significant advantages and benefits, including enhanced flexibility and throughput within automatic storage and retrieval systems. It optimizes space utilization, reduces complexity, and lowers costs compared to traditional methods. Furthermore, it offers precise tension control and synchronous operation for efficient goods storage and retrieval, making it a comprehensive and efficient solution for a wide range of industries.

BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
[0013] FIG. 1 illustrates an exemplary system view of an object carrier transport device for an automatic storage and retrieval system according to some embodiments herein;
[0014] FIG. 2 illustrates an exemplary view of an object carrier transport device for an automatic storage and retrieval system according to some embodiments herein;
[0015] FIG. 3 illustrates an exemplary view of an object carrier for transporting objects between channels of a storage rack according to some embodiments herein;
[0016] FIG. 4 illustrates an exemplary bottom view of an object carrier transport device according to some embodiments herein; and
[0017] FIG. 5 is a flow diagram of a method of transporting an object carrier between different channels of storage racks using an object carrier transport device of FIG. 1 according to some embodiments herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] 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.
[0019] An objective of the current invention is to provide a device and a method for transporting an object carrier between different channels of storage racks 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 for a device and a method for transporting an object carrier between different channels of storage racks. Referring now to the drawings, and more particularly to FIG. 1 through 5, where similar reference characters denote corresponding features consistently throughout the figures, preferred embodiments are shown.
[0020] FIG. 1 illustrates an exemplary system view of an object carrier transport device 100 for an automatic storage and retrieval system according to some embodiments herein. The system view includes a storage rack 102, the one or more object carrier transport devices 100A-N, a conveyor assembly 104 and an object lifting device 106. The conveyor assembly 104 conveys objects from at least one of loading stations and unloading stations. The object lifting device 106 collects at least one object that are conveyed from at least one of the loading stations or the un-loading stations using the object conveyor. The object lifting device 106 transports the objects to at least one level of the storage rack 102. The objects are conveyed from the object lifting device 106 using at least one buffer conveyor. The object carrier transport device 100 collects the objects from the buffer conveyors. An object carrier handles the object from the object carrier transport device 100 and performs at least one storage or retrieval operation. The object carrier transport device 100 transports the object carrier between at least one channel of the storage rack 102. In some embodiments, the object carrier transport device 100 includes one or more tensioners to provide a required tension on at least one of the drive assembly or the conveyor assembly 104. In some embodiments, the one or more tensioners include one or more pulleys that are mounted on object carrier transport device 100 and provide the required tension on at least one belt or chain assembly associated with the at least one of a drive assembly or a conveyor assembly 104 of the object carrier transport device 100. In some embodiments, the object carrier transport device 100 includes a tensioner clamp plate assembly, a chain tensioner assembly, a drive chain assembly and the one or more lock plates. In some embodiments, the one or more lock plates are provided to adjust the tension on at least one of the tensioner clamp plate assembly, chain tensioner assembly, or drive chain assembly without removing the one or more supporting frames of the object carrier transport device 100.
[0021] In some embodiments, the operation of the object carrier transport device 100 is controlled by a control unit. In some embodiments, the control unit includes at least one of one or more controllers, one or more sensors, one or more switches, one or more communication components, one or more power supply components, one or more memory or buffers, one or more cooling components, or one or more display components. In some embodiments, the object carrier transport device 100 simultaneously transports the object carrier into the channels of the storage racks 102 at a single drive or instance. In some embodiments, the object carrier is powered using at least one of batteries or capacitors. The object carrier charges the power resources from the object carrier transport device 100.
[0022] FIG. 2 illustrates an exemplary view of the object carrier transport device 100 for an automatic storage and retrieval system according to some embodiments herein. The object carrier transport device 100 includes an object carrier base frame assembly 202, a driving assembly 204 and an object conveyor assembly 206. The object carrier base frame assembly 202 includes one or more side plates 208A-N, one or more middle supports 210A-N and one or more tube structures 212A-N. object carrier base frame assembly 202 forms a pair of top housings 214A and 214B using the one or more side plates 208A-N and one or more top cover plates 216A-N. In some embodiments, the pair of top housings 214A and 214B accommodates at least one of a cooling fan, a control unit, one or more sensors, one or more indicators, one or more switches, one or more relays, one or more power control devices, or one or more communication devices. In some embodiments, each top housing includes a locking clamp and mechanical slay to close the housing using the one or more top cover plates 216A-N. In some embodiments, one or more recessed handles are provided on the one or more top cover plates 216A-N. In some embodiments, the pair of top housing includes one or more openings. The object carrier transport device 100 runs on the object carrier transport device rail to transport the object carrier between channels of the storage rack 102. In some embodiments, the storage rack 102 includes one or more aisles and one or more channels. The one or more aisles include one or more object carrier transport device rails on each level of the aisle for the object carrier transport device 100. The one or more channels include one or more channel rails for the object carrier.
[0023] In some embodiments, the object carrier base frame assembly 202 is made with sheet metal. In some embodiments, at least one of the one or more side plates 208A-N, the one or more middle supports 210A-N and the one or more tube structures 212A-N are made with sheet metal. In some embodiments, at least one of the one or more side plates 208A-N, the one or more middle supports 210A-N and the one or more tube structures 212A-N are at least one of screw mountable or weldable. In some embodiments, the object carrier base frame assembly 202 is mounted with at least one of the driving assembly 204, the object conveyor assembly 206, one or more guide wheels, one or more buffers, one or more closing frames, one or more motor mount plates, one or more non-drive shafts, one or more tensioner, one or more lock plates, one or more sprocket assembly or one or more chain or belt drive assembly. In some embodiments, the one or more buffers are mounted to an outer side of the base assembly 102 to avoid mechanical damage to the object carrier transport device 100 at an emergency stop. In some embodiments, one or more closing frames are enclosures of the device 100.
[0024] FIG. 3 illustrates an exemplary bottom view of the object carrier transport device 100 according to some embodiments herein. The driving assembly 204 includes a driving motor 302, one or more driving wheels 304A-N, one or more guide wheels 306A-N, one or more bearings 308A-N, one or more chain sprockets 310A-N, one or more chain tensioner roller 312A-N, one or more tensioner clamp plates 314A-N and a driving shaft 316. Both ends of the driving shaft 316 are coupled with the one or more driving wheels 304A-N. The middle part of the driving shaft 316 is coupled with the driving motor 302 using a driving gear assembly. The one or more driving wheels 304A-N are mounted on the one or more side plates 208A-N using the one or more bearings 308A-N. In some embodiments, the object carrier transport device 100 includes at least 4 pairs of driving wheels 304A-N. Each pair of the driving wheels 304A-N are coupled using the one or more chain sprockets 310A-N and chain. Each end of the driving shaft 316 is coupled with the chain sprockets 310A and 310B. In some embodiments, the two pairs of driving wheels 304A-D are driven by the driving shaft 316. In some embodiments, the remaining driving wheels 304E-N are driven on the motion of the two pairs of driving wheels 304A-D. In some embodiments, the remaining driving wheels 304E-N are mounted on the one or more side plates 208A-N using one or more non-drive shafts.
[0025] The one or more guide wheels 306A-N are mounted on the object carrier transport device 100 using one or more guide roller plates. In some embodiments, the one or more guide wheels 306A-N are run on an object carrier transport device rail. In some embodiments, each level of the storage rack 102 includes the object carrier transport device rail. In some embodiments, the one or more chain sprockets 310A-N are provided for balanced load distribution of at least one of the one or more driving wheels 304A-N. In some embodiments, the driving shaft 316 and driving gear assembly are mounted using an enclosure. In some embodiments, the driving gear assembly is assembled in the enclosure and the drive shaft 316 and the drive motor 302 are mounted to the enclosure. In some embodiments, the drive shaft 316 with driving gear assembly are novel design that provides precision movement and high throughput. In some embodiments, each pair of adjacent driving wheels 304A-N is coupled with a chain drive that includes at least one of the one or more tensioner clamp plates 314A-N, the one or more chain tensioner roller 312A-N or the drive chain.
[0026] The object conveyor assembly 206 includes a conveyor motor 318, a conveyor drive shaft 320, one or more conveyor chain sprockets, one or more tensioner sprockets and one or more tensioner sprocket plates. The conveyor drive shaft 320 is coupled with the conveyor motor 318 using a conveyor gear assembly. Both end of the conveyor drive shaft 320 is coupled with the one or more conveyor chain sprocket using one or more flange bearings. In some embodiments, the one or more chain sprockets and the one or more tensioner sprockets are coupled using a chain. In some embodiments, the one or more tensioner sprockets are mounted on the one or more tensioner sprocket plates. In some embodiments, the one more conveyor chain sprockets and the one or more tensioner sprockets are mounted on conveyor side plates. In some embodiments, the conveyor side plates include a close plate. In some embodiments, the one or more tensioner sprockets are adjusted on the one or more tensioner sprocket plates to provide the tension on the chain. In some embodiments, the conveyor drive shaft 320 and the conveyor gear assembly are mounted using an enclosure. In some embodiments, the conveyor gear assembly is assembled in the enclosure and the conveyor drive shaft 320 and the conveyor motor 318 are mounted to the enclosure. In some embodiments, the conveyor drive shaft 320 with conveyor gear assembly are novel design that provides precision movement and high throughput.
[0027] The object carrier base frame assembly 202 includes an object carrier platform that is mounted on the one or more middle supports 210A-N. In some embodiments, the conveyor side plates are mounted with an object carrier guide plate. In some embodiments, the object carrier guide plate is a rail beam. In some embodiments, the rail beam mounts a flat plate for guiding the object carrier on the object carrier transport device 100. In some embodiments, the one or more chain or belt drive assembly is provided to the at least one of the object conveyor assembly 206 or the driving assembly 204 for driving the object carrier transport device 100.
[0028] FIG. 4 illustrates an exemplary view of the object carrier 400 for transporting objects between channels of the storage rack 102 according to some embodiments herein. The object carrier includes an object carrier frame 402, an object carrier driving assembly 404 and an object carrier lifting assembly 406. The object carrier frame 402 includes at least one of top plates, bottom plates, side plates or lifting object plates. In some embodiments, the object carrier frame 402 accommodates at least one of one or more sensors, one or more switches, the object carrier driving assembly 404 or the object carrier lifting assembly 406. The object carrier driving assembly 404 includes an object carrier driving motor, object carrier driving shaft, one or more object carrier driving wheels and one or more object carrier non-driving wheels. Both ends of the object carrier driving shaft are coupled with the one or more object carrier driving wheels using one or more drive sprockets and one or more bearings. In some embodiments, the one or more object carrier driving wheels are coupled and driven using a chain. In some embodiments, the one or more object carrier driving wheels and the one or more object carrier non-driving wheels are mounted on the side plates of the object carrier frame 402.
[0029] The object carrier lifting assembly 406 includes a lift shaft, a lifting motor, a pair of lift cams and one or more lifting blocks. Both ends of the lifting shaft are coupled with the lift cams using plumber blocks. Each lifting block is coupled with two or more lever plates. In some embodiments, the two or more lever plates are coupled with two or more lifting liner plates. In some embodiments, the two or more lifting liner plates couple at least two lifting blocks. The two or more lifting liner plates are coupled using fasteners. In some embodiments, the two or more lifting plates are coupled with the lift cams using at least one of the articulated joint heads or coupling nuts. In some embodiments, the lifting shaft and lifting motor are coupled using an object carrier gear assembly. In some embodiments, the object carrier includes at least one of the object carrier guide wheels, sensors, relays, switches, control units, capacitors or power units. In some embodiments, the object carrier guide wheels are mounted on the bottom plates to guide the object carrier 400 on the channel rail provided on each channel of the storage rack 102.
[0030] FIG. 5 is a flow diagram of a method of transporting the object carrier between different channels of storage racks 102 using the object carrier transport device 100 of FIG. 1 according to some embodiments herein. At step 502, a desired location of objects is determined. At step 504, an object carrier status is analyzed and a channel location of a suitable object carrier is determined. At step 506, device 100 is driven to the channel location to retrieve the object carrier. At step 508, the object carrier is conveyed into the device 100 and drives the device 100 to a channel associated with the desired location of the object. At step 510, the object carrier is conveyed into the channel associated with the desired location of the object for performing retrieval operations. In some embodiments, the operation is repeated for retrieval of the objects from the storage rack 102.
[0031] The object carrier transport device 100 enables manual tension adjustment on the object conveyor assembly 206 and the drive assembly 204 without removing the base assembly 102 or one or more supporting plates 112A-N. The object carrier transport device 100 includes a single frame base assembly 102 which reduces manufacturing resources. The device 100 handles a payload in the range of 500 kilograms to 2000 kilograms.
[0032] 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:1. An object carrier transport device (100) for automatic storage and retrieval to transport an object carrier between channels of storage racks at an instance comprising,
an object carrier that is transported between a plurality of channels of a storage rack (102), wherein the plurality of channels comprises a channel rail for the object carrier, wherein the object carrier comprises at least one of an object carrier frame (402), an object carrier driving assembly (404) or an object carrier lifting assembly (406);
a driving assembly (204) that drives the object carrier transport device (100) on a plurality of aisles of the storage rack, wherein each aisle comprises an object carrier transport device rail;
an object conveyor assembly (206) that conveys objects between the object carrier transport device (100) to a transport conveyor; and
an object carrier base frame assembly (202) that accommodates at least one of the driving assembly (204) or the object conveyor assembly (206), wherein the object carrier base frame assembly (202) comprises a plurality of tensioner adjustment plates that are coupled with a plurality of chain tensioner roller (312A-N) for adjusting tension on at least one of the driving assembly (204) or the object conveyor assembly (206).

2. The object carrier transport device (100) as claimed in claim 1, wherein the object carrier comprises
the object carrier frame (402) that accommodates at least one of a plurality of sensors, a plurality of switches, the object carrier driving assembly (404) or the object carrier lifting assembly (406);
the object carrier driving assembly (404) that drives the object carrier on the channel rail, wherein the object carrier driving assembly (404) comprises
a plurality of driving wheels (304A-N) and a plurality of guiding wheels, wherein the plurality of driving wheels (304A-N) coupled with a driving motor (302) using at least one of a first gearbox, a first drive chain and a first drive shaft; and
the object carrier lifting assembly (406) that lifts up the object carrier, wherein the object carrier lifting assembly (406) comprises
a lifting motor that is coupled with a lifting gear using a chain sprocket;
a pair of lift cams are coupled with each end of a lift shaft using a plumber block; and
at least two pairs of lifting blocks are coupled with the lift cam to lift up and lift down the object when performing at least one of storing and retrieving operation, wherein each pair of lifting blocks are coupled with a pair of liver plate and a liner plate for synchronous operation.

3. The object carrier transport device (100) as claimed in claim 1, wherein the driving assembly (204) comprises
a driving motor (302) that is coupled with a driving shaft (316) using a driving gear assembly;
a plurality of driving wheels (304A-N) that are coupled with the driving shaft (316) using a plurality of sprockets; and
a plurality of guide wheels (306A-N) that are on the object carrier base frame to guide the object carrier transport device (100) on the object carrier transport device rail.

4. The object carrier transport device (100) as claimed in claim 1, wherein the storage rack (102) comprises
a plurality of aisles that comprises a plurality of object carrier transport device rail on each level of the aisle for the object carrier transport device; and
a plurality of channels at each level of the storage rack (102) that comprises a plurality of channel rails for the object carrier.

5. The object carrier transport device (100) as claimed in claim 1, wherein the object conveyor assembly (206) comprises
a conveyor motor (318) that is coupled with a conveyor drive shaft (320);
the conveyor drive shaft (320) is coupled with a pair of conveyor sprockets using a pair of flange bearings; and
a chain that is coupled with the chain sprocket and a tension sprocket.

6. The object carrier transport device (100) as claimed in claim 1, wherein the object carrier base frame assembly (202) comprises an object carrier platform for the object carrier.

7. The object carrier transport device (100) as claimed in claim 1, wherein the object carrier transport device (100) comprises a control unit that receives at least one storage or retrieval signal from the automatic and retrieval system, wherein the control unit is configured to
determine at least one aisle location and channel location associated with objects for performing at least one of storage or retrieval operation;
enable the driving assembly (204) to drive the object carrier transport device (100) to the aisle location when the object is transported from the transport conveyor; and
enable the object carrier driving assembly (404) to drive the object carrier to the channel location, wherein the object carrier collects the object from at least one of the object conveyor assembly (206) or the storage rack (102) using object carrier lifting assembly (406) to perform storage or retrieval operation.

8. A method of transporting an object carrier between channels of storage racks (102) at an instance using an object carrier transport device (100) comprising
determining a desired location of an object;
determining an object carrier status and a channel location of a suitable object carrier;
driving the object carrier transport device (100) to the channel location to retrieve the object carrier;
conveying the object carrier into the object carrier transport device (100) and driving the object carrier transport device (100) to a channel associated with the desired location of the object; and
conveying the object carrier into the channel associated with the desired location of the object for performing retrieval operation.

9. The method as claimed in claim 8, the method comprising
determining at least one aisle location and channel location associated with objects for performing at least one of storage or retrieval operation;
enabling the driving assembly (204) to drive the object carrier transport device (100) to the aisle location when the object is transported from the transport conveyor; and
enabling the object carrier driving assembly (404) to drive the object carrier to the channel location, wherein the object carrier collects the object from at least one of the object conveyor assembly (206) or the storage rack (102) using object carrier lifting assembly (406) to perform storage or retrieval operation.