GB2080265A - Warehousing - Google Patents

Abstract

A materials handling system whereby a number of loads may be stored in and retrieved from narrow aisle racking in one vehicular journey, comprises vertical vertical columns 18 which can carry separate loads and thus act as magazines, which are releasably mounted on trucks 12 or cranes which can receive and release the magazines and which have locomotion and handling means to transfer loads between the magazines and the racking. Empty magazines may be filled with loads to be stored prior to mounting on the trucks and full magazines may be removed from the trucks before being unloaded. <IMAGE>

Description

SPECIFICATION Handling system for magazined, unitised and unit loads This invention relates to the methods and equipment used in Warehousing of goods and in particu lartothe operations involved in the storage and retrieval of loads into and from narrow aisle racking installations.

It is well known for Trucks or Cranes, whether driver operated or automated, to service such installations by picking up a single unitised load from an infeed location at the end of an aisle and taking it down the aisle to a designated or selected empty position in the racking, into which it places the load for storage.

To retrieve a load from storage the Truck or Crane will travel to the position where the required load resides, take it aboard its forks or platen, travel to the end of the aisle and drop it at an outfeed location.

In such applications, the best handling achievable per complete journey of the Truck or Crane is one load in and one load out.

However, it is more often the case that to satisfy the overall Warehouse needs, either STORAGE or RETRIEVAL operations are carried out in specified time periods.

This results in only one load being handled per complete journey of the Trucks or Cranes. In order to minimise the effects of this inefficient procedure it is essential that the pick up and drop locations at the ends of the lanes are well serviced.

The sub systems in use for achieving this are in themselves complex, expensive and space and time consuming.

The invention - is primarily intended to improve the efficiency of storage and retrieval of loads into and from narrow aisle racking installations.

This is achieved by creating a prime handling facility comprising: A. Columns into which unitised loads may be stacked vertically and separately so that a filled column may serve as a transportable load's MAGAZINE AND B. A Truck or Crane, driver operated or automated, having a BREECH structure into which a loaded MAGAZINE may be docked in a securable, releasable manner and having a loads handling means which not only moves vertically and "NORTH & BR< SOUTH" for storing and retrieving unitised loads into and from narrow aisle racking, but can also move "EAST & WEST" to similarly store and retrieve unitised loads into and from the vertical compartments in the MAGAZINE in its BREECH With this facility a preloaded MAGAZINE may be picked up and taken into an aisle and its contents transferred to the racking for storage, whilst other Nanitised loads may be retrieved from the racking and put into the emptied spaces in the MAGAZINE before being released as one unit at the end of a completed journey.

The improvement in efficiency effected through this multiple loads handling facility can manifest itself in more output per unit of time per Truck or Crane, or less Trucks or Cranes to achieve a given output, when compared to existing single load based systems.

The order of improvement is: MEDIUM RISE TRUCK APPLICATIONS 5:1 MEDIUM AREA HIGH BAY AUTOMATED CRANE APPLICATIONS 3:1 If a Magazine is loaded but with one of its compartments left empty, this compartment can receive the first load to be retrieved from a racking space, then without further movement of the Truck or Crane a load for storage can be taken from the Magazine and put to the newly emptied racking space.

This can be repeated during the whole retrievelstore journey plus a pick up of an 'extra' load achieved by bringing the MAGAZINE out of the aisles with all its compartments loaded.

Such a procedure ensures an absolute minimum number of stops en route for the Truck or Crane and by virtue of one particular racking location featuring in a retrieval and a storage activity, the control system is rendered simpler.

It also means that storage and retrieval can, for the firsttime, be effected in 100% full installations.

The same procedure may be used in installations where the racking on either side of the aisles are two deep to improve storage volume utilisation.

In this situation it becomes possible, by going into an aisle with two empty compartments in the Magazine in the Breech, to render the inboard stored loads fully accessible on a random basis.

A further option in two deep racking is to mount two Magazines in line in a special Breech arrangement on an extended Truck or Crane chassis and use the extended "NORTH-SOUTH" reach of the handling means necessary to store and retrieve the inboard loads in the racking, to similarly service, in an "EAST-WEST" operation, the back Magazine.

The invention, in achieving its purpose in respect of improving the efficiency of storing and retrieving loads in narrow aisle racking also provides the facility to similarly improve the sub systems involved in getting unitised loads to the storage pick up location and clearing the retrieved loads from the drop location.

The filling of Magazines with multiple unitised loads for storage and retrieval, whether at random or in predetermined groupings, and the providing of arrangements whereby the Trucks or Cranes may pick up and drop the Magazines without hindrance will have a significant improving effect upon the complexity, cost, space and time factors of the single unitised load handling sub systems used to service existing narrow aisle applications.

The invention offers an opportunity of putting Magazines carrying multiple unit loads to storage as complete units, with an option of retrieving them for removal of their contents or as a 'normal unit' to be handled in the narrow aisle storage and retrieval operations.

It is usual, as distribution facilities become central ised that a multiplicity of systems are necessary to handle the amount and variety of good involved.

By using the Magazine based procedures for stor age and retrieval of unitised loads as the root system, not only will the pick up and drop sub system and the option of Magazine storage racking become available, but the overall Warehouse control and other sub systems such as Automated Order Picking and Manual Order Picking may be related back to the invention to form a total operating system.

FIG. lisa diagrammatic side view of one form of truck.

FIG. 2 is an end view of the truck shown in FIG. 1 FIG. 3 is a diagrammatic side view of an alternative form of truck.

RG. 4 is an end viewof the truck shown in FIG. 3 FIG. 5 is a general view of a medium rise narrow aisle application which embodies the principles of the invention.

FIG. 6 is a perspective view of the form of truck preferred at this time to operate within the invented system as shown in FIG. 5 FIG. 7-10 are plan views of the unitised loads handling means used in the truck of FIG. 6 FIG. 11 is a perspective view showing a high bay crane with features which enable itto operate within the invented system.

FIG. 12 is a perspective view of the crane of FIG. 11 approaching a loaded Magazine.

FIG. 13 is a perspective view of the Magazine of FIG. 12 secured into the breech of the crane of FIG.

11 FIG. 14 is a general view, with racking removed for clarity, of a high bay application of the invention utilising crane transfer means to service more than one aisle per crane and provide a choice of pick up and drop locations.

FIG. 15 is a similar arrangement as FIG. 14 but with an automated in feed and magazine loading facility, an automated magazine unloading facility and an optional means of order picking from the face of 'dropped' magazines.

FIG. 16 is the preferred embodiment of the invention when used in a high bay automated storage and retrieval system. It is fully automated with two in feeds and two outfeeds and employs a carousel system to provide magazines movement to and from the common pick up and drop locations which are at the mouths of each lane.

FIG. 17 is a sub system whereby loaded magazines are stored and retrieved as units using a breech truck and overhead guides.

FIG. 18 is a sub system as FIG. 17 but with the loaded magazines kicking out of the carousel arrangement in FIG. 16 for holding in storage with a means of re-entering the carousel system when required.

FIG. 19 is an automated carousel based magazine loading-storing-retrieving-unloading system.

FIG. 20 is an automated case picking system used to depict how outfed unitised loads from the system using the invention can link up with other necessary sub systems.

FIG. 21 is a schematic layout of a multiplicity of systems which may be installed to advantage in a hybrid warehouse but all affiliated to the root systems and sub systems which are of the invention.

A general view of a medium rise narrow aisle application, which is preferred at this time to embodythe principles of the invention when a truck is used as opposed to a crane, is shown in FIG. 5. A Magazine loading and unloading area is shown at 70 where individual Magazines 72 are being loaded with palletised goods from lorries 74 by conventional stackertrucks76. After a Magazine is loaded it can be raised on to and secured to a truck according to the invention and the truck then conveys it into the storage area 78 of the warehouse. Here it unloads the pallets into selected locations and either picks goods from the area 78 and conveys them in the column back to area 70 for unloading into lorries or returns empty to this area to dock the empty Magazine to area 70 for re-loading with unitised loads for storing in area 78.

Referring now to FIG. 6, the present preferred form of truck to operate in such a facility as in FIG. 5 is shown.

The truck has a most assembly 80 comprising four vertical posts 82 fixed on chassis 12 while Magazine column 18 is securably, removably mounted thereon, by a means not shown, structural member 24 serving as a breech. The driver's seat and control cab 20 can be raised and lowered up mast assembly 80 buy a hydraulic lift 84.

The truck has a control cabin 20 and load bearing and drive wheels 22. Aisle guide rollers 28 are mounted on the chassis 12 to facilitate operation within the racking whilst top guide rollers 26 are mounted on structural member 24to ensure stability during movement and to assist in aisle changing in area 78 and servicing magazine pick up and drop location in area 72.

Load handling means 86 comprises a circulartable 88 mounted centrally for horizontal rotation with respect to an underlying carriage assembly 90. Carriage 90 is supported at each of four corners by chain lifting gear 91 and is guided at each corner by aver- tical post 82 so that it can be raised and lowered up and down the mast assembly in a level condition.

Mounted on table 88 are reciprocable load bearing telescopic forks 92 and safety rails 94. Hydraulic means for rotating the table 88 and means for actuating the forks is provided.

The operation of table 88 and forks 92 is shown in FIGS. 7-10. In FIG. 7, the truck has been brought alongside a palletised load 94 on a storage rack 96.

The table 88 is turned so that the forks face the load, but the forks 92 are in the retracted position since the truck has been in motion. The forks are then extended to engage the pallet (FIG. 8) and the load handling means 86 as a whole raised slightly to lift the pallet clear of the rack. The forks are then retracted, bringing the load over the table 88. This can then be rotated as shown in FIG. 9 until it reaches the orientation shown in FIG. 10 where the forks face a storage compartment 98 in Magazine column 18. The forks are next extended as seen in FIG. 10 and the load lowered on to the supports in compartment 98. The forks are then retracted. Table 88 can also be rotated and the forks extended so as to unload a pallet 100 from the other side of the truck.

Unloading of the Magazine colum and loading of the racks is achieved by reverse operations.

There are two preferred embodiments of the invention when used in high bay crane applications.

The first one is whereby the principles of the invention may be achieved with minimum advancement of the technology of established sys tems.

Referring to FIGS. 11, 12, 13, 14 and 15 to describe the crane embodiment, a number of component parts are similar and bear the same reference num erals as the truck embodiment in FIG. 6.

FIG. 11 shows the crane in its empty state and with a load handling means 86 which utilises a 90" direc tion change as opposed to the turntable movement of this feature of FIG. 6. The arrows V show how the load handling means raises and lowers along mast 80 and the N & S arrows show how the forks slide NORTH & SOUTH for storing and retrieving loads in and from racking slots. Arrows E & W depict how the load handling means 86 travels to store and retrieve unitised loads in and from a magazine when carried.

In FIG. 11 the structural member 24 which serves together with vertical member 101 as a breech for the magazine is part way up mast assembly 80 at a height to suit the magazine column height selected for a particular system.

A device 102 for securing and releasing the magazine into and from the breech is also shown as well as a fixed control cabin which houses the crane controls whether driver operated or automated.

FIG. 12 is included to depict the crane in FIG. 11 approaching a filled magazine column just prior to pick up.

FIG. 13 shows the crane in FIG. 11 in its loads stor age and retrieval operational state with the magazine 18 with its loads 14 in figure 12 secured in its breech.

The arrangement in which the crane 11 could operate is similar to FIG. 6 but options as shown in FIG. 14.

Incoming loads are placed on conveyor 1 by lift truck and pass through sizing check gate 2. If unsuit able the loads will kick off on reject conveyor 3. If suitable they will pass on to transfer car 4. This trans fez car is primarily intended to receive and move cranes to the storage racking aisles (not shown) so that the cranes may switch aisles and also pick up and drop Magazine Columns from the column dock ing face.

However the situation shown at 4 means that a crane carrying an empty Magazine Column can enter the car and load its own column from the car con veyor spur.

Similarly a crane can unload its own column of 'retrieved loads B at car 5 to egress as shown in FIG.

15.

Unitised loads for storage may also be loaded to Breech Columns by lift truck as shown by column D and truck E.

The truck is using a mobile lift platform F as a bridge across trench G to bring the loads to a position where they can be loaded to the Magazine column which is shown in its fully loaded state. This is an option only and truck G may be omitted leaving full access for loading and unloading the magazines as in FIG. 5.

A Magazine column for unloading is waiting at H and when the time comes, the mobile lift platform F will travel to form a bridge in front of the column at H so that the lift truck can strip the column.

The Crane A is in its de-mounted state so would have the option of picking up an empty Magazine Column and loading it itself via incoming conveyor 1 and transfer car 4, or it could transfer along and pick up the column just filled at D.

The second preferred embodiment of the invention, when used in a high bay application, is shown in FIG. 16 and requires significant technological advancement relative to established systems, although the cranes used would be essentially as FIG. 11 with load handling means selected from the options available.

Such an arrangement would operate thus: Loads for storage are placed on FEED CONVEYOR 'A' Pass to load dimension CHECK GATE 'B' If rejected - cleared to CONVEYOR 'C' If O.K. pass to MAGAZINE LOADING STATION 'D' AUTOMATIC MAGAZINE LOADER 'E' Loaded to MAGAZINE 'F' Taken into CAROUSEL SYSTEM 'G' Kicked off to designated SPUR H.l.J.K. or L These spurs have three stations: STATION 1: Where MAGAZINE with loads to be stored waits on arrival.

STATION 2: Where this MAGAZINE is indexed to line up with end of lane.

STATION 3: Where MAGAZINE with retrieved loads waits to be taken into the CAROUSEL system So Crane M is coming out of its lane and is about to dock its Magazine retrieved loads into the vacant STATION 2 on SPUR J.

The procedure is then: CRANE docks MAGAZINE to SPUR CRANE backs clear: SPUR indexed to simultane ouslytakethe retrieved MAGAZINE to STATION 3; the MAGAZINE which was in STATION 3 goes into the Carousel system; the MAGAZINE which was in STATION 1 goes to STATION 2.

CRANE picks up MAGAZINE from STATION 2 and sets off into its Aisle.

Each unit load from the MAGAZINE is stored in the allocated location in the RACKS and on the same journey loads for retrieval are picked from the Racks and put into the MAGAZINE locations vacated by loads just putto storage.

When the storage and retrieval is complete, the CRANE once again comes to the end of its lane where the CAROUSEL system will have ensured, through its computerised control, that the lanes SPUR STATION 2 is vacant to allow the MAGAZINE on the CRANE to be docked.

There are five lanes shown but any number is possible. Under the control of the system computer they all would be operating at the same time. When the MAGAZINES of retrieved loads come back into the CAROUSEL system they index and eventually kick out to the MAGAZINE and transfers them to OUTFEED CONVEYOR P.

The emptied MAGAZINE column will then pass into a queue until it eventually finds itself becoming MAGAZINE F again to receive loads for storage and pass into the CAROUSEL system.

Because of the throughput potential of the five CRANES a second UNITISED LOAD INFEED, MAGAZINE LOAD, MAGAZINE UNLOAD AND UNIT ISED LOAD OUTFEED facility Q and R are included.

Alternative forms of trucks embodying the invention are hereby described.

Referring to FIGS. 1 and 2, a narrow aisle truck comprises a chassis 12, mast 14, handling means 16, demountable magazine column 18, driver's seat and control 20 and load bearing and drive wheels 22.

The mast 14 is fixed and the magazine column 18 is taken aboard and released from chassis 12 by a means not shown and secured to a breech formed by structural member 24. Four rollers 26 are vertically mounted on structural member 24 to engage in guide rails (not shown) which are mounted adjacent to the racks and above the floor of the warehouse on which the truck is designed to operate. Guide rollers 28 are vertically mounted on chassis 12 to prevent collision between the chassis or other parts of the truck with the racks or stacked goods when the truck is being manoeuvred.

Handling device 16 comprises forks 30 carried by a pantograph 32 which at the end remote from the forks is pivotally mounted on a carrier 34. Carrier 34 is mounted for transverse movement with respect to the mast on a carriage 35. Carriage 35 is mounted for vertical movement with respect to the mast, power means being provided to effect this movement.

Figure 1 shows the forks carrying a unit load 36 on a pallet 38. By operating a hydraulic ram (not shown) the load can be moved into the upper compartment of the six compartment Magazine 18 as shown by broken lines at40 in Figure 1. The ram can then be retracted. A load can be extracted from any one of the compartments of the Magazine column 18 by movement of the carriage to an appropriate level of the mast 14 and appropriate operation of the ram and pantograph 32.

To deliver a load to a rack or other packing station at the side of the truck or to take a load from such a location, the forks 30, with the pantograph 32, is swivelled about the carrier 34 and then the carrier 34 is caused to traverse with respect to carriage 35 mounted on the mast so that the forks move transversely of the truck, i.e. to the left or right as seen in FIG. 2.

Referring now to FIGS 3 and 4, an alternative form of truck is shown. A number of component parts are similar and have equivalent functions to those shown in FIGS 1 and 2 and these bear the same reference numerals.

In this embodiment, column 50 is moveably mounted on chassis 12 so that it can reciprocate towards and away from mast 14 which is fixed. A forward support member 52 extends between chas sis 12 and upper structural member 54. Magazine column 50 is securably releasably mounted on a suitable carriage member (not shown), which is moveably mounted on the carriage and actuated by ram means (not shown) while the top of the magazine column 50 is guided by guide means (also omitted) which are secured to the top member and breech 54. To unload a palletised unit 56, load handling means 58 with attached forks 60 are moved hydraulically to the appropriate position on the mast 14 and the magazine column 50, initially in the forward position shown in dotted lines at 62 is moved towards the mast to the rear position shown at 64.

As a result, the forks engage the pallet on which the load is carried. Load handling means 58 raise it clear of the floor of the compartment in the magazine column and the magazine column is returned to the forward position 62. Handling means 58 can then be pivoted about a vertical axis on its mounting 66 and traversed to place the load in racks to the left or right of the vehicle. A load can be picked at the same or a subsequent location and by traverse and pivotting of the handling means 58 and vertical movement as appropriate, brought into register with an open compartment of the magazine. Movement of the magazine column towards and then away from the loading means enables the load to be placed in a magazine compartment.

Both the movement of the magazine whilst aboard the truck and the securing and releasing movements carried out in picking up and dropping off magazines may be achieved by means of a shuttle running along chassis 12, the top of the magazine running in guides on upper member 54 which in this embodiment forms what may be termed a breech truck.

In medium rise applications, the advantages of the invention over previously known systems will be apparent. Previously, it has been necessary for a truckorcraneto move from a loading baytothe storage area to deposit a single load and it can at most pick a single load on the same journey for transport e.g. to despatch area. It must also deposit its load before picking another and so there is no easy way of it replacing, in the same area, the stock it picks with the stock it carries to the storage area. In the embodiments illustrated, the truck or crane of the invention can carry six or seven unit loads to the storage area and on the same journey pick six or seven unit loads from the storage area and transport them to a despatch area. If the truck or crane starts the journey with one compartment of the breech unfilled, it can pick from and refill a single space in a stack or rack without moving from the location. This makes possible the maximum use of storage space and facilitates the cycling of stock.

In the same manner, where the unitised loads are two deep in racking, the truck or crane by virtue of its magazine pick and place facility can, with two empty compartments in its magazine, render the inboard loads fully accessible on a random basis.

A further option in two deep racking is to amount two magazines in line in a special breech arrangement on an extended truck or crane chassis and use the extended NORTH-SOUTH reach of the handling means necessary to store and retrieve the inboard loads in the racking, to similarly service in an EAST-WEST orientation, the back magazine.

In a rising cab, driver operated mode with the load handling means as in FIG 6 the truck may be used as a mobile order picking unit to significant advantage over existing equipment.

Pallets, post pallets, pallet boxes, etc, into which items from various unitised loads in storage racks are to be placed to form an order can be held in the magazine.

The journey can be planned so that as the truck is travelling to a designated racking slotthe article which is to receive some of the items stored there can be brought out on the forks and held at the cor rect height to receive the relevant part of the order.

The operator can not only pick the items from the racking location and put them to the article on the forks but can rotate the load handling means to pro vide maximum accessibility of the receptacle space.

This will be to significant advantage where awkward heavy or small items need to be collected, the prob lem of utilising the space furthest from the operator now being solved by there being no fixed back space to consider.

When a particular requirement has been picked from a pallet slot, if the articles in the next slot along the journey are for collating to a different receptable, the one on the forks can be put back in the magazine to be brought our again later if required and the cur rently needed one brought from the magazine to the picking position.

In such a manner not only can multiple orders be picked on the one journey but the journey itself can be undertaken without any backtracking.

The savings in time, energy, equipment and man ning will be apparent. In particular, a much smaller number of trucks will be needed to service a particu larstorage installation and a decrease in congestion of the storage areas will lead to significant increases in efficiency.

The trucks or cranes according to the invention can handle a variety of loads and service different types of storage installation using rack or stack prin ciples. Palletised loads, intermediate bulk containers and post pallets can all be handled in addition to articles which can be lifted directly by fork gear. The particular loading means used by the truck or crane being selected to suit the loads to be handled within a given application of the invented system.

The number of HIGH BAY WAREHOUSE applica tions is increasing - but the efficiency of their opera tion is decreasing.

This is because there is a move away from storage heights of 30 metres of more to the more technically and environmentally acceptable heights of 15 to 20 metres.

To hold the same volume of goods, the new storage facilities must therefore cover more ground area which manifests itself as longer runs of racking aisles or more aisles, than in the previous higher bay applications. Aisles of up to 300 metres are already in use.

The reduction in storage and retrieval efficiency inherent in this situation is because of the present breed of STACKER CRANES, whether driver oper ated of automated, which are available to operate in these new installations. Generally these cranes spend 50% of their travelling time empty and 50% carrying a single unit load.

Therefore: LONGER AISLES - LESS LOADS MOVED. Although it is possible to transfer cranes between different aisles it is a slow operation which adds even more time and distance to storing and retrieving a single unit load; so often a CRANE for every aisle is installed when the throughput doesn't anywhere near need it.

Therefore: TOO MANY CRANES - HIGH CAPITAL COST. To overcome the present inefficiencies a number of measures are being developed such as faster cranes, computerised routing of cranes to minimise distance travelled and there is one crane which has two sets of forks so that it can handle two unitised loads per journey. The problem with faster cranes is the disturbing effect of acceleration and braking upon the load carried and also the high energy draw such movements require.

The problem with the twin sets of forks crane, apart from the technical, is that the time saved by halving the journey distance is lost in the double pick up and drop operations at the end of the aisles.

By using MAGAZINE COLUMNS in conjunction with stacker cranes in these warehouses, the cranes can be designed to run slower than existing machines, so improving their mechanical reliability and reducing the energy draw; but still move three times the number of unit loads per crane, compared to existing cranes.

This means that more throughput per CRANE, or less CRANES to handle a given throughput, is an option.

A reduction in the number of CRANES to operate a system is possible because an aisle transfer operation, although still slow, is rendered more efficient because multiple loads are being transferred as opposed to a single load or an empty crane.

In a medium installation of 100 metre aisles using MAGAZINE COLUMN STACKER CRANES the throughput per CRANE would be sixty pallet movements per hour which is three times the capability of present CRANES.

In a typical installation, to do the sixty movements, a BREECH STACKER CRANE would travel half a mile less than the horizontal distance covered by a 'normal' one in doing the same movements.

A cause of concern with high bay warehouses is that the economy of ground space achieved by going high is wasted by the inefficient use of space taken up by the sub systems involved in getting the unit loads to the aisle ends for picking up by crane for storage and the getting of retrieved units from the aisle ends for bringing clear of the storage area.

These sub systems involve such articles as ROBOTCARS, ROBOTUGS AND TRAILERS, TRAC TORS AND TRAILERS, PALLET TRUCKS, LIFT TRUCKS etc.

The use of Magazine Columns in a sub system for pick up and drop in multiple load units which can be secured and released'in a single action of the crane represents a significant improvement in time taken, utilisation of space and reduced number of loads movements compared to existing systems.

As an alternative to storing and retrieving indi vidual unitised loads in fixed racking arrangements using securable releasable magazine columns and breech trucks or cranes, there are applications whereby itwould be advantageous to put the loaded magazine columns to storage as complete units and similarly retrieve them when required.

It can be seen that such a facility could serve for handling; SHORT STAY GOODS GOODS AWAITING QUALITY ACCEPTANCE OR GRADING FINITE BATCHES OF GOODS TO BE KEPT TOGETHER EQUIPMENT FINITE PARTS OR SUB ASSEMBLIES KEPT TOGETHER FINITE SHIPMENTS OF UNITISED LOADS KEPT TOGETHER MARSHALLING OF LARGE ORDERS COMPATIBLE LOADS KEPT TOGETHER PERIODS OF HYPER ACTIVITY. PUTTING LOADS TO STORAGE AND/OR RECEIVING LOADS FROM STORAGE LONG ITEMS WHICH CAN BE STORED VERTICALLY (PIPE, BAR, SHEET, CAR EXHAUST SYSTEMS, BATCHES, ETC) Although itwould be feasible to operate a storage/retrieval facility using magazine columns as the only means of racking it is probable that it will be in conjunction with lower cost per slot fixed racking that they will be so used.

There are several options of putting the magazine columns to storage racking duty as the following embodiments will illustrate.

The example of an arrangement whereby laden magazine columns may be stored and retrieved as one unit is shown in FIG 17.

The magazine columns may be loaded at face A by lift truck, taken aboard BREECH TRUCK B and taken into aisle C.

Side spur top guides as shown by D.E.F.G. are arranged along the aisle at right-angles to the centre top guide H and at a height suitable to accept the transfer of the column.

When the truck reaches an empty space on either aisle side, a column release mechanism can be activeted to allow a sideways movement mechanism to transfer the column along the vacant top guide side sputto dock the column in the empty space.

The base of the breech column may be constructed so that it is also located to a base spur guide during column transfer and storage.

Another means of releasing a column to be transferred to a storage location could utilise a rotating base platform to orientate the column through 90 to allow the side transfer mechansim to match the system of picking up the column from face A.

A different release-transfer aid could be based upon a proprietry item such as hydraulically raisable lengths of roller conveyor which are used in container stuffing. These are sunk below container deck level in transit but raised to allow loads to be pushed along the rollers for loading or unloading.

To transfer a column, the roller tracks would lift the column base clear of the truck chassis to line up with fixed roller conveyor on the base of the storage space.

The side shift mechanism would run the column along the raised rollers and top column guide of the truck to transfer to the fixed roller conveyor and top spur guide of the storage location.

Retrieval of columns would be by reverse procedure of storage and on docking into face A they may be unloaded by lift truck.

In a dedicated system the breech truck need not have a separate unit load handling facility such as turntable or pantograph forks. It may be constructed purely as a column handling device.

By not keeping the space necessaryto bring unitised loads out of racks before putting them into spaces in breech columns the column handling trunk could therefore be made shorterwhich could be to cost and operational advantage.

Another arrangement in which unit columns may be stored and retrieved could be in conjunction with an automatic high bay warehousing system such as shown in FIG 16 and is shown in FIG 18.

The columns which are to be stored and retrieved as complete units, instead of passing into the carousel sub-system after being automatically loaded with multiple unit loads at A or Q, kick out on an extension overhead conveyor 1. They then pass to face A from where they may be stored and retrieved by a unit column truck in the system described for FIG. 15.

On being retrieved from storage and docked back into face A, the unit columns could be unloaded by lift truck or pass around the extension conveyor 1 and travel along its return leg 2 to enter the carousel sub-system. The unitised loads carried in the column can then pass into the automated unit load storage and retrieval facility or pass around the carousel to one of the automated column unloading stations P or R. An alternative to storing and retrieving unit columns using a column handling breech truck can also be described by referring to FIG 18.

Instead of stopping at face A the columns for storing would pass around the extension conveyor 1 to its return leg 2 until junction point 3 is reached.

This point is where an aisle top guide, in this case H for aisle C, forms a junction with the extension conveyor return leg.

The column may be switched to the aisle top guide to travel to an empty space than docked.

The carrying device could be slung on the top guide or run on separate guides having a four directional travelling facility to perform the necessary pick up, travel and drop operations.

On retrieval the columns from aisle C would be taken to junction 3 to rejoin the return leg of the extension conveyor Z and then on for high bay warehouse of its multiple loads or automatic unloading at P or R. Such an aisle arrangement could be isolated and protected to operational and environmental safety advantage for storing and retrieving dangerous goods.

Such an arrangement could also be to advantage in other hostile environments where it is desirable to keep human beings clear of as much as possible. For example where the atmosphere could contain irritants to the body and bodily functions.

In this mode also, such storing and retrieving of unit magazine columns offers the potential for high throughput and high energy conservation when used as the operational basis for a COLD STORE.

Another system for storing and retrieving unit columns could be based upon an overhead crane.

The multi directional capability of such a device would provide the means to service a whole bay of aisles and a variety of options such as base guides, pendant column carrying, degree of automation, etc., are available.

If the columns were of an acceptable height it could be possible to eliminate the aisles. The complete floor area could be covered with a honeycomb of column nests.

The crane would be slung so that it could pick up a loaded column and hoist it vertically to more than double its height.

It would than travel in any chosen path over the tops of the mests to whichever one has been selected then lower the column to dock in its nesting place.

For retrieval the procedure is reversed.

Unit columns may also be stored and retrieved as in FIG. 19 This carosel system is based on the same principles as the sub-system of the automated high bay storage and retrieval arrangement shown in FIG 16.

In this case however, the columns keep their loads through their storage period before being called to the automatic unloading station when their contents are required.

Although loads as high as vertical magazine columns would not be allowed on public roads, it would be possible to transport them by a special vehicle in such fashion within a building or between buildings on the same premises.

Columns carrying long goods may be sized to fit as a grid into an I.S.O. container. For example a container 8' HIGH x 8' WIDE x 20' LONG could accept four breech columns suitable reduced for clearance fitting from a 4' x 4' x 20' module.

In this "lying down" orientation the columns could similarly be loaded on to lorry decks or deep sea transport.

With suitable load protection, such as shrink wrapping the complete column it could be possible to eliminate the container altogether.

if the columns were carrying individual unitised loads, which were themselves shrink wrapped or otherwise secured and of such a nature asto accept "lying down" at 90"to their normal orientation without detriment, then this mode of transportation would be feasible for them too.

It has been described how it could be to advantage to augment a facility for storing and retrieving individual unitised loads using fixed racking and securable-releasable magazine columns handling trucks or cranes, with an additional facility for storing and retrieving magazine columns as complete units.

In the same way, even such a combination in itself might not provide flexibility, reliability, and efficiency requirements of modern large distribution centres.

Normaliy a proportion of the unitised loads stored and retrieved will not be despatched as whole units but will need to be 'broken' to provide separate items which will be required to form the mixed unit loads to satisfy varying customers orders.

It is necessary in these cases to provide a suitable Order Picking facility.

Such a facility is shown in FIG 10. It can be seen the systems infeed conveyor could well be the outfeed conveyor R of the unit load storage and retrieval system in FIG 16forexample.

This particular automated system takes unitised loads of common packages, strips them and puts them to individual lanes for storage.

Packages required for a particular order are picked from the delivery ends of the lanes and pass to accumulate on a conveyor from which they are taken unitised to form the mixed order.

There are many options of systems and subsystems which may be used to form a particular hybrid warehouse.

FIG 21 is a schematic arrangement of a hybrid warehouse using magazine column handling as the root system.

Such an arrangement might operate: Incoming unitised loads at A loaded to conveyor B.

If acceptable to the unit load storage-retrieval system the load pass on so that the automatic breech column unit D loads them to the column at station E or the loads pass to C and on to a transfer car conveyor from where a breech truck or crane may self load its secured empty breech column.

Whether obtained from a column loaded at E or conveying one which has been self loaded, the breech truck or crane can store its multiple unit loads in and retrieve multiple unit loads from the fixed racking installation G using transfer along F for cross movement.

Retrieved coluns may be docked into face H or unloaded automatically at station J by means of device I to egress on conveyor K.

An alternative could be for the truck or crane to unload itself via the clearing conveyor on the transfer car, the loads then also passing on to conveyor K.

Complete unit loads for despatch may be taken from the conveyor K, in the direction of arrow L for marshalling for transportation whilst those required for order picking can pass to strippinglcollating station Q.

If a facility for carousel warehousing unit columns is required, filled columns may be taken from Station M into sub-station N, held until required then brought back to station M for putting units to store or bringing to station J for stripping.

A carousel buffer such as 0 may take system overspill loaded columns andlor contain empty columns whether new or re-jigged or empties temporarily not needed put to reserve stock. Column from 0 may be re-entered into the main system at Station M.

Instead of entering the system at A, unit loads which are designated for break up for order picking may travel to P where they achieve the same status as the unit loads coming out of the main system from conveyor K, and similarly pass to stripping/collating station Q.

Areas 2 and 3 are separated cells of an automated picking facility using the same principles as in FIG 20 whilst slow moving items for picking have been transferred via the automated lanes to a bank of lanes running under and with opposite pitch to egress at face Y from where they may be picked manually.

It could also beto operational advantage to keep some partly depleted unitised loads in static racking as shown in area 2.

The options are many and varied but it can be seen thatthe multiple load handling afforded by the invention provides an important root system for the efficient operation of a modern warehousing facility.

Claims (32)

1. A materials handling system comprising: Columns into which unitised loads may be stacked vertically and separately so that a filled column may serve as a transportable load's MAGAZINE.

AND A mobile Truck or Crane, driver operated or automated, having a BREECH structure into which a loaded MAGAZINE may be docked in a securable, releasable manner and having a mast mounted, power operated, controlled loads handling means which not only moves vertically and "NORTH & BR< SOUTH" for storing and retrieving unitised loads into and from narrow aisle racking, but can also move "EAST & WEST" to similarly store and retrieve unitised loads into and from the vertical compartments in the MAGAZINE in its BREECH

2. A materials handling system as claimed in claim 1. wherein the load handling means comprises a set of forks or a platen, pivotably mounted on the mast for direction of horizontal travel and incorporating pantograph feature to achieve the reach movements.

3. A materials handling system as claimed in claim 1. wherein the load handling means comprises a set of forks or a platen which slides NORTH & BR< SOUTH mounted on a carriage which slides on a bed to achieve EAST & WEST movement.

4. A materials handling system as claimed in claim 1. wherein the load handling means comprises telescopic forks mounted on a horizontally rotatable turntable which can be raised and lowered with respect to the mast.

5. A materials handling system as claimed in claim 1. wherein the handling device moves reciprocally with respect to the mast either by means of or additionally by means of a traversing facility mounted on the mast

6. A system according to any one of claims 1. to 5. wherein the magazine is held static in the breech of the truck or crane and the mast can move towards and away from it.

7. Asystem according to any one of claims 1. to 5. wherein the mast of the truck or crane is fixed in relation to the chassis and the magazine can reciprocate towards and away from it.

8. Asystem according to any one of claims 1. to 5. wherein both the mast of the truck or crane and the magazine it carries are moveablewith respectto the chassis.

9. A system according to claims 1. to 5. wherein a double distance reach capability is incorporated into the truck or crane load handling device so that the system may operate in narrow aisle racking with loads held two deep from the aisles.

10. A system according to claim 9. wherein two magazines are mounted in line in the breech of the truck or crane.

11. A system according to any one of the preceding claims wherein the securable releasable magazine is in the form of a column having more than three similar compartments, one above the other, each constructed to receive a unit load.

12. A method of transporting multiple unit loads to and from vertical storage racks wherein a truck or crane carries individually accessible multiple loads and, on a single journey, handling means on the truck places unit loads carried by the truck or crane individually in the racks.

13. A method according to claim 12 in which the handling means, on the same journey, removes unit loads individually from the racks and transports them on the truck or crane from the storage area.

14. A method of transporting multiple unit loads and putting them to storage as one unit and similarly retrieving and transporting them from storage.

15. Asystem according to claim 14 wherein the magazines are handled by a similar mobile truck or crane as in any of the preceding claims.

16. Asystem according to claim 14wherein the magazines are handled by overhead conveying means.

17. A system according to claim 14 wherein the magazines are handled by a carousel arrangement incorporating a power and free overhead conveying and top guide facility and an option of additional floor guide and support means.

18. A system according to claim 14 wherein the magazines are handled by overhead crane.

19. A system wherein the facilities claimed in claims 14 to 18 are used to provide a feedstock of magazined loads for use within any of the systems claimed in claims 1. to 13.

20. A system wherein the facilities claimed in claims 14to 18 are used to receive, hold and give up individually accessible unit loads as a sub system to any of the claims relating to claim 1.

21. Asystem according to claims 1. to 13. and also claim 19. wherein the truck or crane component is driver operated from a cab which has the capability of rising and lowering along the mast to enable articles to be manually picked from the loads in the racking and placed into a receptacle brought from the magazine in its breech on any of the unitised load handling arrangements previously claimed.

22. A system according to claims 1. to 13., 19. & 20. is constructed to operate with securable releasable magazine which are of the same height and compartmentation as a vertical row of unitised l6ad' slots in the fixed racking it serves. -

23. A system according to claims 1. to 13. and 19.

& 21. wherein the truck or crane carries a breech arrangement for securable releasable magazines which are of a lower height then the fixed racking which it serves, with a mast and unitised load handling means which can operate at the full height of the racking.

24. A system according to claims 1. to 13. and 19.

to 23. wherein the truck or crane picks up and drops magazines from and to a docking leading and unloading face which runs at right angles to the fixed racking aisles.

25. A system according to claims 1. to 13. and 19.

to 24. wherein the cross movement of a truck or crane to achieve the selection of a docking location is facilitated by tacking through an overhead and floor guides switching arrangement.

26. A system according to claims 1. to 23. and 19.

to 24. wherein the cross movement of a truck or crane is achieved via a transfer car means.

27. Asystem according to claims 1. to 13. and 19.

to 23. wherein pick up and drop of magazines is facilitated by bringing the magazines to the truck or crane by means of a carousel.

28. A system according to claim 1. to 13. and 19.

to 24. wherein pick up and drop of magazines in respect of the aisle working struck or crane is facilitated by a mobile magazine handling truck.

29. A system according to the preceding claims wherein individual unitised loads are stripped from and loaded to a magazine secured in the breech of a truck or crane, via a roller conveyor arrangement

30. A system according to the preceding claims wherein individual unitised loads are stripped from and loaded to magazines by automated devices.

31. A system according to claims 1. to 13. and 19.

to 26. whereby articles may be picked from the face of the docked magazines for mixed requirements.

32. A system according to any of the preceding claims wherein retrieved unitised loads are further processed within a sub system which uses the main system according to claim 1. as the root warehouse operation and control system.