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CN106575391A - 机器人物品处理系统、设备与方法 - Google Patents

机器人物品处理系统、设备与方法 Download PDF

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CN106575391A
CN106575391A CN201580044136.5A CN201580044136A CN106575391A CN 106575391 A CN106575391 A CN 106575391A CN 201580044136 A CN201580044136 A CN 201580044136A CN 106575391 A CN106575391 A CN 106575391A
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斯威克·林德伯
安德鲁·约翰·英格拉姆-泰德
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Abstract

本发明描述了一种机器人物品处理系统和在其上操作的机器人负载处理设备（30、50a）。所述物品处理系统包括可在网格状结构（20）上操作的多个机器人负载处理设备，所述结构包括设置在堆叠的箱子蜂巢之上的多组平行轨道（22a、22b）。所述箱子包含将由系统拣选的库存货品。能够运载具有单个网格间隔尺寸的多个箱子或具有多个网格间隔的单个箱子的负载处理设备在计算化的订单拣选实用程序的控制下可在网格上操作并取出和运输箱子。

Description

机器人物品处理系统、设备与方法
本发明涉及一种机器人物品处理系统、设备与方法，具体但不仅限于涉及在机器人物品处理系统中使用的一系列机器人设备，以及扩大可以在这种系统中处理的货品种类的方法。
本申请针对于2015年4月15日提交的第GB1506364.7号英国专利申请和2014年6月25日提交的第GB1411254.4号英国专利申请要求优先权，其内容均通过引用被纳入本申请中。
一些商业与工业活动需要能够存储与取出大量不同产品的系统。一种已知的在多个产品线中存储与取出货品的系统包含将存储箱子或容器一个压一个的堆成堆垛，所述堆垛成排放置。从上方存取存储箱子或容器，这样成排容器之间就可以不需要通道，容许在给定的空间存储更多的容器。
人们已非常了解处理成排堆放的容器的方法。在一些此类系统中，例如在发明人贝特尔的US2701065中所述，包括成排放置的独立容器堆垛，以减少与存储此类容器相关联的存储体积，但是仍可以根据需要存取专用容器。通过提供可以用于堆叠和迁移来自堆垛的指定容器的相对复杂的举升机构可以存取一个指定容器。然而在很多情况下，此类系统在成本上是不切实际的，而且，这些系统大部分已在存储与处理大型船运集装箱上商业化。
目前已经研发出使用独立式的容器堆垛并提供取出与存储专用容器的机构的方案，例如Cimcorp的EP0767113B所述。Cimcorp公开了一种使用矩形管式机器人负载处理机迁移数个堆叠的容器的机构，所述矩形管式机器人负载处理机可降低至所述容器堆垛周围，且被配置为能够抓取所述堆垛中任一层的一个容器。这样，就能从一个堆垛中同时提升几个容器。可移动的矩形管可用于将几个容器从一个堆垛的顶部移动到另一个堆垛的顶部，或从一个堆垛移动到一个外部位置，反之亦然。当单个堆垛中的所有容器中存放的是同一种产品时（也称为单一货品堆垛），此类系统尤其有用。
在如‘113中所述的系统中，所述矩形管的高度必须至少与最大的容器堆垛一样高度，这样才能在一次操作中取出最高的容器堆垛。因此，在用于诸如仓库等密闭的空间时，所述堆垛的最大高度受容纳负载处理机矩形管之需所限制。
EP1037828B1（Autostore）描述了一种容器堆垛排放在框架结构内的系统，其内容通过引用被纳入本申请中。此类系统说明示意图见附图1-4所示。机器人负载处理设备可以在所述堆垛的最上部表面上的轨道系统上可控地围绕所述堆垛移动。
挪威第317366号专利对所述机器人负载处理设备的一种形式进行了进一步的说明，其内容通过引用被纳入本申请中。附图3（a）与3（b）分别是负载处理设备后面与正面立体示意图，附图3（c）是提升箱子的负载处理设备的正面立体示意图。
2014年7月24日提交的第GB1413155.1号英国专利申请描述了负载处理设备的进一步发展，其中每个机器人负载处理机仅占用一个网格空间，因此允许负载处理机的密度更高，从而给定尺寸系统的吞吐量更高。
现有技术系统的一个主要缺点是其只能使用具有指定占用空间的容器。此外，容器的高度通常受到所述机器人负载处理机的设计的限制。这通常使这种系统限于使用于适应所述容器内部的物品。在典型应用中，这意味着业务总量的1-10％需要不同的处理方法，通常是手动的。这意味着系统的复杂性增加、生产率低且空间利用效率低。本发明通过提供在主要设计用于大量较小货品的系统内集成用于小量较大产品的解决方案的方式来解决这些问题。
在典型的零售或包裹处理情况下，上述系统可以处理大多数但不是所有的产品或包裹。对于大多数产品而言，理想的是使用约600×400×350mm（长×宽×高）的标准容器，因为该尺寸的容器通常容纳90-99％的所有产品，并且足够小，以在需要时可以手动处理。该尺寸的容器还足够小以在给定尺寸的建筑物中提供非常大量的容器，因此便于处理非常大量的不同产品。在现有技术系统的一些情况下，也可以将正常高度容器和较矮容器混合使用。其目的是增加给定尺寸系统中的容器的数量，这在某些条件下是有利的。
根据本发明，提供了一种物品处理系统，包括在数个堆叠的容器上方形成网格的两组基本上垂直的轨道，所述堆垛的一部分包括具有比所述堆垛的其余部分中的容器更大的横截面积的箱子，所述处理系统还包括在堆叠的容器上方的所述网格上操作的数个机器人负载处理设备，所述负载处理设备包括安装在轮子上的主体，第一组轮子被设置成与所述第一组轨道的至少两个轨道接合，第二组轮子被设置成与所述第二组轨道的至少两个轨道接合，所述第一组轮子可相对于所述第二组轮子独立地移动和驱动，使得当运动时，在任何时间只有一组轮子与所述网格接合，从而使得通过只驱动该组轮子与轨道接合而使所述负载处理设备沿所述轨道移动到所述网格上的任何一点，可在所述网格上操作的至少一个机器人处理设备的尺寸被设计成从包含大容器的堆垛的部分内提升和移动容器。
根据本发明，还提供了一种机器人负载处理设备，其包括具有腔室的主体，所述主体包括安装在所述主体的垂直侧面上的两组轮子，每组轮子可相对于另一组轮子独立地缩回和驱动，所述主体中的腔室的尺寸被设计成能接受来自物品拣选系统的容器，所述物品处理系统包括设置在数个容器堆垛上方的网格，所述主体中的腔室的尺寸被设计成接受具有由所述物品处理系统中的整数个网格间隔限定横截面积的容器。
这样，容器的高度就不再受所述机器人负载处理机的尺寸的限制。有了较高的容器，例如600×400×800mm，就可以处理许多不能装入正常容器中的物品。
现在将参照附图对本发明进行描述，其中：
附图1是已知存储系统中存放数个箱子堆垛的框架结构的立体示意图；
附图2是附图1所示框架结构一部分的平面示意图；
附图3（a）与3（b）分别是与图1和图2所示的框架结构一同使用的一种机器人负载处理设备的后视和前视立体示意图，图3（c）是使用中的提升箱子的已知负载处理设备的立体示意图；
附图4是已知存储系统的立体示意图，其包含设置在附图1与2所示的框架结构上的附图3（a）、3（b）与3（c）所示类型的数个负载处理设备；
附图5是已知存储系统的立体示意图，其包含设置在附图1与2所示的框架结构上的附图3（a）、3（b）与3（c）所示类型的数个负载处理设备，所述框架结构包含不同尺寸的箱子；
附图6a是正常箱子的立体示意图，附图6b是能够承载由本发明的一种形式的负载处理机移动的较大尺寸货物的不同尺寸的较高箱子的立体示意图；
附图7是根据本发明的一种形式的能够运输如附图6b所示的箱子的负载处理设备的示意图；
附图8是如附图7所示的可在网格上操作的负载处理设备与具有正常尺寸的负载处理设备混合使用的立体示意图，所述堆垛包含正常尺寸的箱子和高尺寸的箱子；
附图9是在如附图1和2所示的网格上操作的本发明的第二种形式的负载处理设备的示意图，所述第二种形式的负载处理设备在所有尺寸上都比正常负载处理设备大（展示以用于比较）；
附图10是选择相对正常箱子不同尺寸的大容器的示意图，大容器可以存储在所述堆垛中以由根据本发明的其它形式的负载处理设备取出；
附图11是根据本发明的第三个实施例的提升大容器的大负载处理设备的示意图；
附图12是根据本发明的一种形式的从不同高度的大箱子堆垛提升大箱子的大负载处理设备的示意图；
附图13是具有大箱子区域和大箱子的一些站以及仅包含正常尺寸的箱子和负载处理设备的区域和站的网格系统的示意图。
如附图1与2所示，可堆叠的容器，即箱子10，一个叠一个地堆放形成堆垛12。所述堆垛12排放在仓库或生产环境中的网格框架结构14中。附图1是所述框架结构14的立体示意图，附图2是所述框架结构14中排放的箱子10的堆垛12的俯视图。每个箱子10一般都放有数个产品（图中未显示），每个箱子10中的所述产品可以是同种产品，也可以是不同种类的产品，依实际情况而定。
所述框架结构14包含数个支撑水平构件18、20的垂直构件16。第一组平行的水平构件18与第二组平行的水平构件20垂直，形成数个由所述垂直构件16支撑的水平网格结构。所述构件16、18、20通常由金属制成。所述箱子10堆放在所述框架结构14的所述构件16、18、20之间，以使所述框架结构14可以防止箱子10形成的所述堆垛12的水平移动，并控制所述箱子10的垂直移动。
所述框架结构14的最顶层包括横越所述堆垛12顶部的网格状轨道22。另见附图3与4所示，所述轨道22支撑数个机器人负载处理设备30。平行轨道22的第一组22a用于引导所述负载处理设备30沿第一方向（X轴方向）移动穿过所述框架结构14顶部，平行轨道22的第二组22b与所述第一组22a垂直，用于引导所述负载处理设备30沿垂直于所述第一方向的第二方向（Y轴方向）移动。这样，所述负载处理设备30就可以在所述轨道22上沿X-Y二维面内的两个方向进行移动，因此，负载处理设备30就可以移动到任一个堆垛12上方的位置。
每个负载处理设备30都包含一个运载工具32，用于在所述堆垛12上方所述框架结构14上的所述轨道22上沿X轴方向与Y轴方向滑动。第一组轮子34包含所述在运载工具32正面的一对轮子34，以及在所述运载工具32后面的一对轮子34，用于与所述轨道22的第一组22a的两个相邻轨道接合。同理，第二组轮子36包含所述运载工具32每侧的一对轮子36，用于与所述轨道22的第二组22b的两个相邻轨道接合。每组轮子34、36都可以抬升或降低，使所述第一组轮子34或所述第二组轮子36可以在任何时候分别与所述轨道22a与轨道22b接合。
当所述第一组轮子34与所述第一组轨道22a接合，所述第二组轮子36就会抬升，脱离所述轨道22。所述轮子34由内置在所述运载工具32中的传动机构（图中未显示）驱动，沿X轴方向移动所述负载处理设备30。要沿Y轴方向移动所述负载处理设备30，所述第一组轮子34抬升，脱离所述轨道22，所述第二组轮子36降低，与所述第二组轨道22a接合。随后所述传动机构便可用于驱动所述第二组轮子36沿Y轴方向移动。
这样，一个或多个机器人负载处理设备30可以在中央拣选系统（图中未显示）的控制下在所述框架结构14上的堆垛12的顶部表面到处移动。每个机器人负载处理设备30具有用于从所述堆垛抬升一个或多个箱子或容器以存取所需产品的工具。这样，就可以在任何时候从所述网格和堆垛中的多个位置存取多个产品。
从上面的描述并参照附图能注意到，由轮子承载的负载处理设备30的部分覆盖所述堆垛上方的所述网格系统的一个网格间隔。
附图4展示了如上所述的典型存储系统，该系统具有在堆垛12上活动的数个负载处理设备30。
在本发明的第一实施例中，使用较高的机器人负载处理机。现在将参考附图6至8描述的高机器人负载处理机设备50。与参照附图1至5描述的负载处理设备共有的所有项目将使用相同的标号。
这些较高的负载处理设备的尺寸被设计成运载类似于附图6所示的箱子。附图7展示了提升高箱子的高负载处理设备。在将箱子提升到堆垛的顶部时，箱子位于负载处理设备的主体内。所述负载处理设备50保持与正常负载处理设备相同的尺寸，因为设备的轮子部分占用堆叠的箱子上方的轨道系统的一个网格间隔。这样，所述堆垛可以包含不同高度的箱子，被移动到网格间隔的所述高负载处理设备在需要时取出高箱子。正常高度的设备可以根据需要继续取出正常高度的箱子。
附图8展示了可在堆垛上方的网格上操作的多个高负载处理设备以及多个正常尺寸的负载处理设备。应当注意，所述堆垛包含不同高度的箱子。然而，所有的箱子在堆垛中占用的位置是单个网格间隔的占用面积。
应当理解，与正常的机器人负载处理机相比，这些较高的负载处理机可能具有较差的机械稳定性，但是如果加速度和速度适当降低，这是可以接受的。
对于较大的货品，本发明的另一实施例提供了一种具有跨越一个以上网格空间的机器人负载处理机的解决方案。这可以例如是2、4、6、8或9个网格空间，表示为2×1、1×2、2×2、2×3或4×2、2×4或3×3个网格空间。在下面的示例中，将仅描述具有2×2个空间的占用面积的负载处理设备的情况。然而，应当理解，所述较大的负载处理设备可以占用任何数量的网格间隔。为了充分利用用于正常和较大机器人负载处理机的集成系统，这些大负载处理设备50a将被设计为在与正常负载处理机相同的网格结构上行进，如附图9所示。
大负载处理设备可以设置有多组轮子34、36。
如附图9所示，较大的2×2网格间隔占用面积的负载处理设备可以在具有其它正常单个网格间隔占用面积的负载处理设备的网格上操作。所述2×2负载处理设备50a设置有第一组轮子34，包含在所述运载工具50a的相对的平行侧上的多对轮子34。所述轮子34被设置成与轨道22的第一组22a的三个相邻轨道接合。
同样，提供第二组成对的轮子36，该组轮子包含在所述运载工具的相对侧上的成对的轮子36，这些相对侧基本上垂直于所述运载工具的第一组相对侧。轮子36被设置成与轨道22的第二组22b的两个相邻轨道接合。
每组轮子34、36都可以抬升或降低，使所述第一组轮子34或所述第二组轮子36可以在任何时候与相应的轨道组22a、22b接合。
如附图9所示，大负载处理设备可以在与正常负载处理设备相同的网格上操作。然而，在附图9中，所述设备将提升具有单个网格间隔尺寸的多个容器。
如附图11所示，在使用中，所述大负载处理设备可以提升大约1300×900mm的容器，假定位于单个网格间隔中的正常容器为600×400mm，并且堆垛之间的间隔为100mm。这些2×2网格间隔容器就可以具有不同的高度，以容纳不同尺寸的产品。例如，这些大容器的高度可以是300mm、500mm和1000mm，如附图10所示。
附图10中所示的较大的2×2网格间隔的箱子不能堆叠在有较小的1×1网格间隔的箱子的堆垛中。相反，正常的1×1网格间隔的负载处理设备不能穿过大容器的堆垛上方的空间。根据本发明的该实施例的典型系统将具有专用于正常容器和正常机器人负载处理机的大部分设施。将有用于较大容器的货品进入、拣选/包装和分派的少量工作站，以及专用于大容器的相对少部分的存储空间和其上方的相应网格。附图12和13展示了这种布置。
在使用中，所述大机器人负载处理设备在堆垛上方的网格上正常工作，但仅在所述堆垛仅包含具有较大占用面积和多个高度的箱子的位置处从所述堆垛提升大箱子。
所述负载处理设备将较大的箱子从所述堆垛中提升到所述负载处理设备的主体内的腔室中，使得箱子被提离所述堆垛上方的网格。
应当理解，上述机器人负载处理设备仅是本发明的实施例。可以考虑能在存在多种高度可能性的区域中运载具有任何多个网格间隔的箱子的负载处理设备。
上述拣选系统可以涉及诸如为在线零售设计的订单拣选系统，或者可以涉及诸如包裹处理和分类系统的系统。应当理解，本发明适用于项目以堆叠的结构存储在容器中并且可以由机器人处理设备存取的任何系统。

Claims (7)

1.一种物品处理系统，包括在数个堆叠的容器上方形成网格的两组基本上垂直的轨道，所述堆垛的一部分包括具有比所述堆垛的其余部分中的容器更大的横截面积的箱子，所述处理系统还包括在所述堆叠的容器上方的所述网格上操作的数个机器人负载处理设备，所述负载处理设备包括安装在轮子上的主体，第一组轮子被设置成与第一组轨道的至少两个轨道接合，第二组轮子被设置成与第二组轨道的至少两个轨道接合，所述第一组轮子可相对于所述第二组轮子独立地移动和驱动，使得当运动时，在任何时间只有一组轮子与所述网格接合，从而使得通过只驱动该组轮子与轨道接合而使所述负载处理设备沿所述轨道移动到所述网格上的任何一点，可在所述网格上操作的至少一个机器人处理设备的尺寸被设计成从包含大容器的所述堆垛的一部分内提升和移动容器。
2.根据权利要求1所述的物品处理系统，其中所述负载处理设备包括能够提升和运输多种高度的容器的主体。
3.根据权利要求1或2所述的物品处理系统，其中所述至少一个负载处理设备包括跨越约1×2、2×2、2×3或3×3个网格间隔的主体，所述网格间隔由基本上垂直的轨道组的间隔来限定。
4.根据任一项前述权利要求所述的物品处理系统，其中所述容器在由所述负载处理设备运输时位于所述负载处理设备的所述主体内的腔室中。
5.一种用于权利要求1至4中任一项所述的物品处理系统的机器人负载处理设备。
6.一种机器人负载处理设备，其包括具有腔室的主体，所述主体还包括安装在所述主体的垂直侧面上的两组轮子，每组轮子可相对于另一组轮子独立地缩回和驱动，所述主体中的腔室的尺寸被设计成能接受来自物品处理系统的容器，所述物品处理系统包括设置在数个容器堆垛上方的网格，所述主体中的腔室的尺寸被设计成接受具有由所述物品处理系统中的整数个网格间隔限定的横截面积的容器。
7.一种参照附图6至13如上文所述的机器人负载处理设备或物品拣选系统。
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