Description

Device and method used to pick up. handle and store packages in an automated warehouse.

The present patent application relates to a device and method used to pick up, handle, and store packages in an automated warehouse.

As it is known, a warehouse comprises a plurality of shelves, racks compartments or recesses where packages are stored and ordered either individually or in lots. An automated warehouse provides for a device used to pick up, handle and store packages in the corresponding spaces.

The said device generally comprises a handling means, such as a shuttle, a rack feeder or a truck, designed to move along the warehouse lanes both in horizontal and vertical direction. The handling means is provided with two parallel flat rods, normally defined as forks, that are situated under the package to be handled. The forks are translated by means of a telescopic sliding system.

Since packages are generally supported by standardised pallets, the forks are arranged at a predefined mutual distance in such a way to be inserted in the slots of the pallet.

The known devices are designed to pick up, handle and store one package at a time. To that end, the two forks are actuated simultaneously and always make the same predefined travel. In fact, since they pick up one package at a time, at every picking the device moves according to the position and dimensions of the package to be picked, being inserted under the pallet.

This inconvenience is solved, at least partially, by more advanced devices that pick up all the packages that are situated in the warehouse space simultaneously, without the possibility to select the individual packages during the unloading operation. The said known devices are impaired by a severe constraint during unloading, since they must unload all the packages stored in the warehouse space simultaneously. This requires to define and

prepare the lot during loading, without the possibility to make future changes. It appears evident that such a known device is unsuitable for a large warehouse with intense activity, in which a large quantity of packages must be handled in the shortest time possible and lots composed of multiple packages must be created during unloading, when shipment has been defined according to the final requests from the customer.

The purpose of the present invention is to eliminate the inconveniences of the known technique, by devising a device and method to pick up, handle and store packages in an automated warehouse capable of managing multiple packages at the same time, including with different dimensions, and without the need to group the packages in advance.

Another purpose of the present invention is to provide such a device that does not require a loading bay to prepare the packages or a pallet to support the packages. These purposes are achieved by the present invention with the device and method whose characteristics are listed in the enclosed independent claims 1 and 8.

Advantageous embodiments of the invention are disclosed in the dependent claims. The device used to pick up, handle and store packages in an automated warehouse according to the invention comprises: a support frame arranged on a handling means designed to move in the warehouse, forks slidingly mounted on the support frame and designed to be situated under the package to be picked, and

- actuation means to remove the said forks. The device comprises at least three forks that are actuated telescopically and independently, in such a way to simultaneously pick up multiple packages with different dimensions. The advantages of the device according to the invention appear evident, since it allows for the simultaneous handling of multiple packages with different dimensions.

The device of the invention allows for:

- reliable handling of packages with any type of packaging by means of a lifting movement, without sliding; using the maximum storage capacity, optimising the position of the packages in the shelf, without the need to group lots; storing the packages in the warehouse independently from the production mode and without the need to prepare lots in advance. Therefore, the production of some components from the same lot can be done at a later stage; - making lots with multiple packages both during loading in the warehouse and unloading from the warehouse and change them, if necessary simplifying the entrance station that does not need to consider the incoming lots and product type; - picking one or more packages from the warehouse, with the possibility to prepare the lot to be shipped with the desired flexibility, without the use of loading bays; reordering and optimising the layout of the packages in the warehouse rapidly, during the hours with lower activity in the warehouse. Moreover, it must be noted that the device of the invention is perfectly scalar and modular, and can be expanded by adding new modules according to storage and performance requirements.

The use of the device of the invention allows for eliminating the use of pallets, since the space necessary to insert and remove the telescopic elements is directly obtained on the support surface of the shelves.

Additional characteristics of the invention will appear evident from the following detailed description, which refers to merely illustrative, not limiting embodiments, illustrated in the enclosed drawings, wherein:

Fig. 1 is a diagrammatic perspective view that illustrates the device used to pick, handle and store packages in an automated warehouse, according to the present invention;

Fig. 2 is a partially interrupted, diagrammatic top view that illustrates a

first embodiment of the device of the invention; and

Fig. 3 is the same as Fig. 2, except for it illustrates a second embodiment of the device of the invention.

With reference to the aforementioned figures, a device used to pick, handle and store packages in an automated warehouse is disclosed, according to the invention, globally referred to with numeral (1 ).

The device (1) comprises a rectangular support frame (2) arranged according to a horizontal plane.

The frame (2) is mounted on a handling means, such as a truck, a shuttle or a rack-feeder of known type, not shown. The handling means is designed to move in the warehouse. For example, the handling means can translate in linear direction:

- along a first horizontal axis (X) parallel to the longest sides of the frame (2), - along a second vertical axis (Y), and

- optionally, also along a third horizontal axis (Z) orthogonal with respect to the first axis (X).

A plurality of guide tracks (3) is mounted on the frame (2), consisting in sections with basically U-shaped cross-section. The guide tracks (3) are arranged in parallel position. The ends of the guide tracks (3) are fixed at the longest sides of the frame (2), in such a way that the axes of the guide tracks

(3) are orthogonal to the horizontal translation direction (X) of the frame.

For illustrative purposes, the figure illustrates twelve regularly spaced guide tracks (3), although any number of guide tracks can be provided, not necessarily being spaced regularly.

A first support rod (4), hereinafter defined as intermediate rod, is slidingly mounted on each guide track (3), being composed of a section with basically H-shaped section. The intermediate rod (4) is translated on the guide track (3) by means of drive means (30), such as a belt or chain drive, actuated by a motor (7), as illustrated hereinafter.

The intermediate rod (4) can translate on either side with respect to the frame (2) in the direction of the arrows (Z). Suitable stops limit the maximum

travel of the intermediate rod (4) in the maximum extraction position on either side with respect to the frame (2). Preferably, the intermediate rod (4) is as long as the track (3), in such a way to be arranged in a position with minimum volume over the track (3). A second rod, normally defined as fork, is slidingly mounted on each intermediate rod (4), consisting in a section with basically T-shaped cross- section. The upper surface of the fork (5) is provided with a flat smooth plate to slide under the packages (C1 , C2, C3, C4) to be picked. The drive means (30) of the guide track (3) also extends through the intermediate rod (4), in such a way to actuate the fork (5) and translate it on the intermediate rod (4).

The fork (5) can translate on either side on the intermediate rod (4) in the direction of the arrows (Z). Suitable stops limit the maximum travel of the fork (5) in the maximum extraction position on either side with respect to the frame (2). Preferably the fork (5) is as long as the intermediate rod (4), in such a way to be arranged in a position with minimum volume on the intermediate rod (4).

It must be noted that the guide track (3), the intermediate rod (4) and the fork (5) form a telescopic system that allows for extracting the fork (5) on either side with respect to the frame (2). The movement of each fork (5) is controlled independently with respect to the movement of the other forks (5). The said device (1 ) can be used to pick multiple packages (C1 , C2, C3, C4) simultaneously, enabling the translation of the forks (5) only towards the packages to be picked.

Moreover, the travel of each fork (5) is controlled independently with respect to the travel of the other forks (5). In this way, the device (1) can be used to simultaneously pick multiple packages (C 1 , C2, C3, C4) with different shapes and dimensions, adjusting the travel of each fork (5) according to the size and shape of the package to be picked.

The example of Fig. 1 illustrates the simultaneous picking of four packages (C1 , C2, C3, C4) with different size.

Starting from the left-hand side of the figure, the first two forks slide forward, almost to the stop, to pick the package (C1 ).

Since the package (C2) is longer and narrower than the package (C1), four forks with a lower travel than the first two forks are actuated to pick the package (C2).

Since the package (C3) is sufficiently short and arranged at a certain distance from the package (C2), the seventh and the eighth fork remain in idle position, whereas the ninth fork is actuated to be positioned under the package (C3).

Finally, the tenth fork is stopped and the last two forks are actuated to be positioned under the package (C4). In this way the device (1) can simultaneously pick a lot of four packages (C1 , C2, C3, C4).

It must be noted that the device (1) is especially suitable to be used in a warehouse of modular kitchens, for example, in which components of different size are provided to form a kitchen, which can be typically referred to a "lot" and includes a number of individual packages with different size ranging from 5 to 15 or 20. To that end, the device (1) is preferably provided with a number of forks (5) that normally, yet not necessarily, varies from 8 to 15.

As illustrated in Fig. 2, in order to actuate the forks (5) individually and with different travels, the actuation means (7) can provide for a plurality of electrical motors (70), each of them connected to an individual fork (5). The electrical motors (70), for example, are arranged with the axis of the drive shaft in orthogonal position to the forward direction of the forks (5). The pinion of each motor (70) engages with a belt or chain drive (71 ) that drives into rotation a shaft (72) on which the corresponding belt or chain drive (30) of the guide track (3) is returned.

Each motor (70) is mounted jointly under the guide track (3), or the frame (2) near the guide track (3).

Each motor (70) is actuated by means of a processor controlled by the user according to the number and shape of packages to be picked.

Evidently, the belt or chain drive systems can be replaced with other types of transmission systems, such as screw/mother screw, pinion/rack, and

similar systems.

Moreover, in order to actuate the forks (5), the electrical motors (70) can be replaced with linear actuators, such as cylinder-piston assemblies of hydraulic, pneumatic or electromagnetic type. Fig. 3 illustrates a second embodiment of the invention, in which the same elements or elements that correspond to the ones described above are indicated with the same reference numerals, omitting a detailed description.

In this case the actuation means (7) comprise only one electrical motor (170). The pinion of the motor (170) engages with a belt drive (171) that drives into rotation a drive shaft (172) with ends supported revolvingly on the opposite sides of the frame (2). The drive shaft (172) is arranged under the guide tracks (3) with axis orthogonal to the forward axis of the forks (5).

The shaft (172) is provided with a plurality of pinions, each of them engaging in the corresponding drive means (30) of each guide track (3). Each pinion can be connected/disconnected from the drive shaft (172) by means of a friction gear (173). The friction gears (173) are actuated by means of a processor controlled by the user. Consequently, according to the number and shape of the packages to be picked, the user shall enable/disable the friction gear (173) to control the movement of the fork (5). Numerous variations and modifications can be made to the present embodiments of the invention by an expert of the field, while still falling within the scope of the invention as claimed in the enclosed claims.