Storage system and methods

Patent metadata

Field	Value
Publication number	US-9643780-B2
Application number	US-201213680221-A
Country	US
Kind code	B2
Filing date	Nov 19, 2012
Priority date	Nov 20, 2011
Publication date	May 9, 2017
Grant date	May 9, 2017

Abstract

A storage system includes a rack with a plurality of layers, each layer including an aisle and a plurality of rows extending from the aisle defining storage locations for items. A shuttle usable with the rack includes a first cart movable along the aisle and a second cart configured to be carriable by the first cart and to be movable along a row. The second cart is configured to carry an item between the first cart and the storage locations. A conveyor is located on one of the first or second carts to move the item onto or off the first cart. Related methods of storing and/or retrieving items from a rack are also disclosed. A rack system is disclosed and is readily assembled without welding, transferring loading so that the weight of the rack and any item stored therein is supported by the upright elements via support brackets.

First claim

We claim:

1. A system for storing and retrieving items comprising:
a rack including a plurality of layers, each layer including an aisle and a plurality of rows extending substantially perpendicular from the aisle, the items being storable in storage locations along the rows, each aisle having a loading position at one end and transfer positions located along the aisle adjacent ends of the rows;
a shuttle on each layer, at least one of the shuttles being a dual shuttle including a first cart movable along the aisle between the loading position and the transfer positions, the dual shuttle including a second cart configured to be carried by the first cart between the loading position and the transfer positions, the second cart movable in either direction between a transfer position and a storage location along a row while carrying an item;
a first cart conveyor located on the first cart operable when the first cart is at the loading position to move the item onto or off the first cart, the first cart conveyor being an endless loop conveyor;
a lift substantially adjacent the rack for lifting items to the respective loading positions for the layers, the lift including a lift platform having a lift platform conveyor for moving items off the lift platform and toward the loading positions of the respective layers, the lift platform conveyor being an endless loop conveyor; and
each layer of the rack including a rack conveyor adjacent the loading position for transferring items between the lift platform and the loading position, the rack conveyor sized to as to be able to hold at least one item thereon so that the rack conveyor can move items onto one of the lift platform conveyor and the first cart conveyor while the second cart is located in a given row, the second cart being independently drivable off the first cart to perform at least one of placing or retrieving an item in the given row while the first cart moves along the aisle spaced from the given row.

2. The system of claim 1 , wherein the second cart is located on the first cart when the first cart conveyor is operated.

3. The system of claim 1 , wherein the first cart conveyor moves the item directly onto the first cart.

4. The system of claim 1 , wherein the first cart has a first motor for moving the first cart along the aisle and a second motor for driving the first cart conveyor.

5. The system of claim 4 , wherein the first and second motors of the first cart are AC motors.

6. The system of claim 1 , wherein the second cart has a raisable top platform, a first motor for moving the second cart along the rows and a second motor for selectively raising the top platform to lift an item.

7. The system of claim 6 , wherein the top platform can be lifted to remove an item from the first cart when the first and second carts are located at a transfer position so that the second cart can carry the item to a storage location in the respective row.

8. The system of claim 6 , wherein the top platform can be lifted to retrieve an item from a storage location in a row so that the second cart can carry the item to the first cart, the first cart then carrying the item to the loading position for transfer out of the rack.

9. The system of claim 6 , wherein the top platform is raised by a camming device that rotates around a horizontal axis.

10. The system of claim 6 , wherein the first and second motors of the second cart are AC motors.

11. The system of claim 1 , wherein the second cart has an energy storage device for storing energy used to power the second cart.

12. The system of claim 11 , wherein the energy storage
device in the second cart is a charged via electrical contact between the second cart and the first cart.

13. The system of claim 11 , wherein the energy storage device in the second cart is charged via electrical contact between the second cart and the rack.

14. The system of claim 11 , wherein the energy storage device is a battery.

15. The system of claim 11 , wherein the energy storage device is a capacitor.

16. The system of claim 1 , wherein the dual shuttle is powered by electrical contact between the dual shuttle and the rack.

17. The system of claim 1 , wherein the second cart is powered so as to move along a row while the first cart moves along the aisle.

18. A system for storing and retrieving items comprising:
a rack including a plurality of layers, each layer including an aisle and a plurality of rows extending substantially perpendicular from the aisle, the items being storable in storage locations along the rows, each aisle having a loading position at one end and transfer positions located along the aisle adjacent ends of the rows;
a shuttle on each layer, at least one of the shuttles being a dual shuttle including a first cart movable along the aisle between the loading position and the transfer positions, the dual shuttle including a second cart configured to be carried by the first cart between the loading position and the transfer positions, the second cart movable in either direction between a transfer position and a storage location along a row while carrying an item, the second cart having a raisable top platform, a first motor for moving the second cart along the rows and a second motor for selectively raising the top platform to lift an item;
a first cart conveyor located on the first cart operable when the first cart is at the loading position to move the item onto or off the first cart, the first cart conveyor being an endless loop conveyor;
a lift substantially adjacent the rack for lifting items to the respective loading positions for the layers, the lift including a lift platform having a lift platform conveyor for moving items off the lift platform and toward the loading positions of the respective layers, the lift platform conveyor being an endless loop conveyor; and
each layer of the rack including a rack conveyor adjacent the loading position for transferring items between the lift platform and the loading position, the rack conveyor sized is as to be able to hold at least one item thereon so that the rack conveyor can move items onto one of the lift platform conveyor and the first cart conveyor while the second cart is in a given row, the second cart being independently drivable off the first cart to perform at least one of placing or retrieving an item in the given row while the first cart moves along the aisle spaced from the given row.

19. The system of claim 18 , wherein the top platform can be lifted to remove an item from the first cart when the first and second carts are located at a transfer position so that the second cart can carry the item to a storage location in the respective row.

20. The system of claim 18 , wherein the top platform can be lifted to retrieve an item from a storage location in a row so that the second cart can carry the item to the first cart, the first cart then carrying the item to the loading position for transfer out of the rack.

21. The system of claim 18 , wherein the second cart is powered so as to move along a row while the first cart moves along the aisle.

Assignees

• Illinois Tool Works

Inventors

• Salichs Rafael
• Tamayo Juan Carlos

Classifications

• B65G1/026

  Racks equipped with a displaceable load carrying surface to facilitate loading or unloading · CPC title

• B65G1/065 Primary

  with self propelled cars · CPC title

• B65G1/06

  with means for presenting articles for removal at predetermined position or level (B65G1/12 takes precedence) · CPC title

• B65G1/0492

  with cars adapted to travel in storage aisles · CPC title