GB2052456A - Warehouse installation - Google Patents

Abstract

A warehouse installation comprising a support structure having pigeon-holes aligned along longitudinal corridors (1). First trucks (18a) are displaceable into and out of the pigeon-holes and onto platform (27) of a second truck (26) which is displaceable along a corridor (1). The platform (27) of the second truck (26) comprises mechanical means (29) ensuring the displacement of the load (17) in the direction of the length of the corridor (1) and lifting means (30) permit the transfer of the load (17) from the platform (27) on the first trucks (18a) and vice-versa. <IMAGE>

Description

SPECIFICATION A warehouse installation The evolution of merchandise traffic, influenced by that of means of transport and the general use of pallets, tends to promote the development of large selling surfaces and of large halls for stocking merchandise where the operations of entry, of emplacement and of outlet are more or less automated.

Often, this merchandise arrives direct from the manufacturer who makes the goods in more or less constant quantities in accordance with its potential, and delivers in very irregular quantities in accordance with the needs of the market which varies greatly with the product under consideration and the season.

The best modern means such as: punched cards, card indexes, computers, etc., especially permitting immediate information as to where and since when each product has been stocked, to operate in such a manner that for each type of product the first input into the store is also the first to come out, to establish the inventory of the products and the movements, and greatly facilitating the administration operation.

Moreover, certain of these installations permit constituting the loading of each pallet which comes out according to its destination, and grouping thereon goods which have arrived on different pallets from the same or diverse sources.

In view of the cost of land and of construction, it is important that the land is well used and that the ratio between the outside volume of the building containing the store and the useful volume stocked is kept to a minimum, which can be obtained by a very high storing density.

Numerous systems have been proposed. In certain cases, the storage volume is cut by several service corridors equipped with mechanical means permitting direct access to all the locations situated on each side of the corridor. This system has the advantage of permitting direct access to each location of the store; the time necessary to place or remove a pallet is fairly short if the installation comprises sufficient mechanical devices. But it has the inconvenience of being fairly onerous, as the factor of utilization of the volume is not at all favourable, due to the fact of the presence of numerous corridors, and that it is necessary to equip several corridors, if not all, with a mechanical installation so as to ensure sufficient speed.

In other cases, the stock volume which has the form of a rectangular parallelepiped is effected in columns, on several rows and several levels. The installation comprises a portable structure of corresponding form on which each pallet is deposited. A first corridor permits the access to all the compartments of the last row and serves as an entry for pallets which are disposed in each of these compartments. A second corridor placed in front of the first row of the structure is used for the outlet of the merchandise.Each column of the structure is slightly inclined from the rear towards the front, the pallets are resting via an auxiliary truck or comprising an appropriate mechanical system, in such a manner that the pallet deposited in one compartment of the last row automatically advances in the column, until it occupies the first free compartment and arrives at the first row from where it will be removed. In this case, the products are classified chronologically along each column. The principal "First in-First out" is automatically respected. This system has the advantage of good entry and exit speeds and a good use of the space, for as long as the number of rows of one column of pallets is sufficiently large. It has the inconvenience of necessitating a mechanical system tied to the fixed structure or to the pallets for the displacement of these along one column.The stocking principal "First in, First out" is however a serious handicap, and it implies that all the pallets situated in one and the same column contains all the same product, conditioned in the same manner, and which has the inconvenience of only authorising a partial filling of numerous columns, and reduces by the same amount the factor use of the volume.

Finally, warehouses have been proposed where a machine circulating in a corridor permits the removal of any pallets stocked, on several rows and several levels, and this from one or both sides of a corridor. If these systems have the advantage of a good use of the volume and of the time admissable for the exit of the pallet, it has the inconvenience of calling for complicated mechanical systems tied to the carrying structure, for laterally disengaging the pallets placed in the same column and in front of the one searched for and thereby rendering it accessible.

This lateral displacement is fairly difficult as, in accordance with the case it can concern all the columns of the pallets of the warehouse.

Cold stores having low or very low temperatures where the conservation is effected for example as -30 C poses, in addition to the same problems as above, otherwise difficult constraints, connected to the exceptional temperature. In effect, these stores must be simultaneously automatic to reduce or to avoid the presence of personnel in the warehouse, and very reliable, as a failure of one member, even a minor one could cause damage and involve considerable cost, out of proportion with the value of the said member. Moreover, the use factor in volume must be particularly high, as the value properly named of the volume, is added to the maintenance costs of the base temperature, costs which increase with the outer surface area of the warehouse.

According to the present invention there is provided a warehouse installation for merchandise disposed on pallets or in containers constituting loads, comprising a merchandise entry zone and exit zone, which zones can be merged, comprising: a support structure providing transverse pigeon-holes disposed on at least one level, adjacent each other, and aligned along a longitudinal corridor, these pigeonholes comprising a storage surface on which loads are disposed and on which at least a first truck rolls transversely which, during storing, transports loads one after the other from the corridor and disposes them in the base of the pigeon-hole and conversely during their removal; said first truck having support wheels at least one of which is driven and a part which can be inserted under the load to lift it, transport it and dispose it; at least a second truck displaceable along the corridor, equipped with a platform which can be brought into position as an extension of the storage surface of the pigeon-holes, on which surface the first truck rolls to pass from the pigeon-hole to the platform and can be brought in front of another pigeon hole or another means for transporting the loads from the entry or taking them towards the exit; the surface of the platform of the second truck being sufficiently large to simultaneously support all the loads which can be placed in one pigeon hole, this platform comprising mechanical transfer means permitting the displacement of the loads along the axis of the corridor, the part of the platform of the second truck on which the first truck rolls, at the exit or at the entry of the pigeon-hole, being able to be lowered by a height sufficient to dispose the load transported by the first truck on the transfer mechanism of the second truck and to avoid the first truck forming an obstacle to the longitudinal transfer of the load on the platform.

The present invention will be described further, by way of example, with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of the fixed support structure of a warehouse; Fig. 2 is an end view of a storage pigeon-hole; Fig. 3 is a perspective view of a first transfer truck; Fig. 4 represents a variation of the embodiment of this first truck; Fig. 5 is a plan view of the second transfer truck for access to the pigeon-hole located on one side of the corridor; Fig. 6 is a plan view of the variation of the second truck for access to the pigeon-holes located on both sides of the corridor; Fig. 7 is a sectional view of one storage level showing the function of the first and second trucks; Fig. 8 is a variational embodiment of the second transfer truck; Fig. 9 is a plan view of a corridor with a transfer truck;; Fig. 10 is a plan view of a corridor with two manoeuvring trucks permitting each access to the pigeon-hole situated on both sides of the corridor; Fig. 11 is a front elevation of an administration tower and of a second manoeuvring truck combined with a load lifter; Fig. 12 is a side elevation of the administration tower and of a second manoeuvring truck combined with a load lifter; and Fig. 13 is a plan view of the administration tower and of a second manoeuvring truck combined with a load lifter.

Fig. 1 shows, in perspective, the support structure showing the disposition of various pigeon-holes in which the loads can be disposed. The term "load" covers all the members which can be used for the stocking and the administration of merchandise dis posed on pallets, placed in containers etc. The weight of these loads, which is often a ton, can be as much as two or perhaps three tons in accordance with circumstances. The stocking volume is, in the case of this figure, divided into two partial volumes situated one on each side of a central plane, each of these partial volumes is cut into by a corridor 1,2. In each corridor, a first truck carried by a second truck is displaced for positioning in front of a pigeon-hole constituting the head of a column where the compartment is found or where a pallet is to be deposited or removed.

By corridor, the installation can comprise as many rolling track for second trucks as there are stocking levels, solution of Figs. 9 and 10, or even a single rolling track a solution of Figs. 11, 12 and 13.

The stocking is effected in accordance with three principal directions: x(3) is a transverse direction, Y(4) is a longitudinal direction, Z(5) is an elevational direction. The two storage blocks having the references 6 and 7 for the first, and 8 and 9 for the second.

The literal numbering of the drawing permits, taking into account the reference numerals of the blocks (6, 7,8 or 9), the designation of each compartment of this stocking assembly, for example in the compartment 8; X = c, Y = f, Z = b is determined with precision. The reference 10 designates a pigeon-hole which is found in the block 9, comprises four cases, the four compartments a, b, c, d in accordance with X, d in accordance with Y, b in accordance with Z.

Figure 2 shows, by way of example, one arrangement of a support structure. This is constituted by uprights 11 which are supported on the ground and carry via members 12, a floor sheet 13 at various levels. These are represented here as if they were constituted of a flat sheet folded at the ends at 14 and 15, and reinforced by several stiffening ribs 16.

The folded borders 14 and 15 can serve to guide the load in the form of a pallet 17 during its displacement along the pigeon-hole and contribute to the rigidity of the assembly.

In Figure 2 the floor 13 of the pigeon-hole is constituted by a sheet, but it could be made in another way, for example by profile members, the construction being lightened thereby. The guiding of the load 17 by the folded edges 14 and 15 of the sheet 13 could be made differently, in particular by welding auxiliary ribs 14', 15' guiding the central wood rib of a pallet 17, as is shown at the top of the Figure 2.

Figure 3 shows an embodiment of the first truck which has the same appearance as a well-known "transpallet" truck. It is differentiated by the fact that its carrying wheels 20a are fixed with respect to forks 19a, and on the other hand, these forks 19a include cylindrical rollers positioned side-by-side on each of the arms at 21 a, 22a and 23a on each fork. These rollers are adapted to facilitate the lateral transfer of the load when it is on the second truck.

The truck 18a moreover comprises jacks 24a and 25a situated on each of the arms 19a, between the rollers 21 a, 22a, 23a. These jacks 24a, 25a, carried by the fork, comprise a piston with a bearing surface which can be lifted with respect to the fork. These jacks 24a and 25a could be placed in other positions than those represented in the drawing and, espe cially could operate on each arm between two rollers placed one beside the other.

The functioning of the truck is as follows: After it has been positioned under a load 17, the jacks 24a and 25a are lifted by the effect of a suitable electroc control. The bearing surfaces of the jacks 24a, 25a are displaced vertically, lifting the pallet 17 and the weight of the load is transferred to the truck 18a which, by rolling, can displace it along a pigeon-hole. The jacks 24a, 25a of the truck 18a can be mechanical, hydraulic or pneumatic.

The truck in accordance with Figure 4 functions in the same manner as the known "transpallet". The mechanism which it comprises, is not visible in the drawing, is situated in the forks and the head of the truck. In accordance with known procedures, it effects the lifting or the lowering of the carrying surfaces of the truck. The functioning of this truck is the same as the preceding arrangement and it is remotely controlled by means of an electric connecting cable.

Figure 5 shows an embodiment of the second truck with access only to the pigeon-hole situated on one side of the corridor. This truck 26 rolls on two rails 35 in the longitudinal direction of the corridor 1 or 2. Its platform 27 comprises three parallel bands 28 of cylindrical rollers 29, having axes perpendicular to these bands, which facilitate the transfer of the loads which rest thereon. This second truck 26 comprises, moreover, a lifting platform 30 fixed to the truck 26 via lifting jacks, not shown in the drawing, permitting vertical displacement of about 6 centimeters of this platform 30.

When the first truck 18a, which carries the load 17, is at the same level as the lifting platform 30 of the second truck, placed in its highest position, and they are aligned, the truck 1 8a receives an order to withdraw. It leaves the pigeon-hole and rolls onto the platform 30 of the second truck into the position shown in chain dotted lines in Fig. 5 of the drawing.

Then, the platform 30 is lowered onto the second truck 26 up to the end of its course, in which position, the rollers 29 of the second truck 26, as well as the rollers 21a, 22a, 23a of the first truck 18a are in the same horizontal plane. This then provides a practically unbroken parallel transporting band. It is then sufficient to rotate these rollers to effect the displacement to the load which they carry along the axis of the corridor. This load can thus be displaced progressively towards the left hand end of the second truck 26, the length of which is chosen in such a manner that it can receive at least all but one of the loads, which can be placed in a pigeon-hole.

Thus, to remove the load which occupies, for example, the fourth row from a pigeon-hole, first of all the three loads of the same column disposed towards the front of the pigeon-hole are taken out, they are provisionally stocked on the left hand side of the truck 26. Then, when the fourth load is brought out by the truck 18a, the rollers 28 are rotated in the opposite direction so that the load will be displaced towards the right of the truck 26 and will occupy a position on the right hand band 33 constituted in the same manner as the left hand bands 28. The three loads placed to the left are then brought back one after the other and replaced in the pigeon-hole by opposite movements to those by which they were taken out.When this operation is finished, the second truck is displaced along the corridor to dispose the load in the base thereof on another mechanical transverse means which brings it to the exit zone of the warehouse, using means well known, not shown in the drawings.

To avoid the waiting time due to the re-positioning of the loads occupying the first rows of the pigeonhole and disposed provisionally on the left hand side of the truck, the right hand side of the second truck 26 can be separated therefrom and constitute a third truck 31 the platform 32 of which carries three bands of transporting rollers 33 situated at a same level as the bands 28 of the second truck. This third truck 31 rolls on the same rail 35 as the second truck 26, can be displaced to the right and effect without delay the transfer of the load from the second truck towards the mechanical outlet device.

The transporting of the load by the bands of rollers is well known, these rollers being rotated by electric motors some directly the others via a flexible transmission member, such as a cable, chain, belt or cog wheels. Instead of using bands of rollers it is possible to replace them by belts or transporting chains.

For stocking in a store and the replacing of the load in their pigeon-holes, the same operation as above is effected but in the reverse order.

Fig. 6 shows a variation the functioning of which is the same as Fig. 5. It is distinguished by the fact that the elevating platform 30 which can be raised or lowered with respect to the second truck 26, can also turn around a vertical axis. These lifting and rotational movements can easily be effected in using a cylindrical jack having a vertical axis, as represented in the drawing by a circle 34.

In the case of this figure, instead ofthree bands of rollers 28, the construction only has two parallel bands carrying the load at their ends.

The installation permits the truck 18a to enter into the pigeon-hole situated on both sides of the service corridor. To this end, after having lifted the platform 30 with respect to the platform 27 of the second truck 26 it suffices to pivot it around itself by a half revolution, as indicated in chain dotted lines, so that it presents itself in front of the entrance of the pigeon-hole situated on the opposite side of the corridor This pivoting is obtained by known means not shown in the drawing.

Figure 7 represents the truck of Fig. 6, in end view, and the rolling tracks, seen in transverse section. The installation is completed by parts such as the jack 34 which permits raising and lowering of the platform 30 with respect to platform 27 of the truck 26 and to permit its rotation around a vertical axis. On the other hand, the drawing shows that the elevating platform 30 is equipped at one of its ends, with an abutment 36 avoiding the first truck going too far in its course and, at the other end with a ramp 37 pivoted with respect to the lifting platform 30, ramp which, controlled by jacks, not shown in the drawing, rotate around a horizontal axis and can be lowered and put into a horizontal plane for facilitating the rolling of thefirsttruck 18a outofthe pigeon-hole onto the platform 30, and conversely. This ramp 37 is lifted during the longitudinal displacement of the second truck along the corridor, as well as during vertical or rotational displacement of its lifting platform 30 with respect to the truck 26.

Figure 8 is a variation ofthis second truck adapted to receive a first truck in accordance with Fig. 4, not having any rollers on the upper face of its forks. This second truck comprises the same parts as that in accordance with Fig. 7, but here the lifting platform 30 is lowered, after having done only a quarter of a turn around its pivotal axis. In this position, the load rests only on the two outer bearings of the pallet on the rollers of the zone encircling the lifting platform 30 where their length has been reduced. In this embodiment, the two or three bands of Figs. 5 and 6 have been replaced by a single band 28 of long rollers 29, except in the zone of the lifting platform 30.

The functioning of the installation is, in general terms, the same as the preceding one. The rotation of the elevating platform 30 by a half turn around the pivotal axis permits the first truck access to the pigeon-holes situated on both sides of the corridor, whilst the rotation by a quarter of a turn on this axis puts the load in position to be transported in one or in another direction of the corridorto the left to be put in waiting, or to the right to be removed possibly by means of a third truck 31, equipped with rollers 33.

Figure 9 is a view of the assembly of the installation in accordance with Fig. 5, it shows, situated at the end of the corridor a load lifter 38 for receiving load carried by the truck 31 and to lower ortho raise it vertically, or for disposing it on another means for trasporttowards the exit. The platform of this loadlifter 38 is represented here in the form of a fork which, when its arms are conveniently inserted underthe load, can, after a slight lifting course, take up the load, free the third truck which can then be brought back towards the second truck to receive the next load.

Figure 10 is a view of the assembly of the installation in accordance with Figs. 6 and 8 showing the arrangement of the pigeon-holes situated on both sides of the corridor equipped with a rolling track 35.

In this case, installation comprises two plafforms 26 independent one of the other, each equipped with a lifting platform 30, which can remove loads from both sides of the corridor and each having a third auxiliary truck 31.

The doubling of these plafforms permits accelerating the unloading ofthe merchandise at the entrance and at the exit. The lateral ends of the track 35 can be equipped with load lifter 38 similar two the one shown in Fig. 9 or of any other mechanical device ensuring transfer of merchandise towards the outlet or bringing these to the entry zone.

Figs. 11,12 and 13 represent a movable tower equipped with a platform constituting a second truck. In this case, the rolling truck 35 is a single one for all the storage levels. The mechanical installation is constituted in the form of a tower displaceable along the rail 35, carrying a vertical upright along which the platform 27 is displaced. Here, the third truck which, in the preceding figures, was displaced horizontally, is replaced by a load lifter 39 which brings the loads to the platform 27 or removes them therefrom to dispose them on a transfer device, for example, between the rails constituting the track 35, a transfer device as shown in the drawing, in the form of a rolling carpet or a transporting band having rollers or other systems.

The functioning of the installation is the same as before; it is distinguished therefrom however by the platform 27 which can be brought in front ofthe pigeon-holes discharging from the corridor by vertical displacement above the tower, and by longitudinal displacement of the tower on its track. This tower has access to the pigeon-holes situated on a single side of the corridor. As precedingly, it should have been possible to equip the platform 27 with a pivoting lifting platform 30 which can access both sides of the corridor, thefirsttrucks being those ofthetype 18a of Fig. 3 or 18b of Fig. 4.

Proceeding further, notwithstanding that it is not shown in the drawing, the installation comprises a building which surrounds the store and, if it is necessary, thermal imstallation from the outside air.

Likewise, the zones where the storage is effected are provided, possibly surrounded, with transfer means ensuring the transport of the loads at the entrance to the warehouse during the stocking and conversely during the removal of stock moreover, the installation can comprise permitting modification of the loads of the outcoming pallets.

The installation can be automated in the sense that all the operations effected for placing a load in a particular compartment, and its removal from this compartment, can be controlled consecutively in the order required, for example, by a computer which can be provided with the memory in which all the operations effected are written. The access to this memory permits instantaneous updating ofthe inventory of the store and monitoring of the products for stock control.

Finally, access to the compartment to the first range being more rapid than those ofthe compartments of the last rows, it is attractive, during the exit of a load stocked in the pigeon-hole, to rest the loads in the pigeonholes which have been momentarily removed, the furthest to the end of the pigeon-holes possible, so as to leave free the compartments of the first rows of pigeon-holes, which would permit accelerating the emplacement of the new loads entering the store.

Likewise, as the removal of the loads from the store are effected in accordance with certain provisions, it is possible to perceive a control system such that, for example, during the waiting time, the mechanical installation modifies the order of rows of the loads in the pigeon-holes in a mannerto place in the first rows, the loads which are demanded for a future removal.

Claims (13)

1. Awarehouse installation for merchandise disposed on pallets or in containers constituting loads, comprising a merchandise entry zone and exit zone, which zones can be merged, comprising: a support structure providing transverse pigeon-holes disposed on at least one level, adjacent each other, and aligned along a longitudinal corridor, these pigeonholes comprising a storage surface on which the loads are disposed and on which at least a first truck rolls transversely which, during storing, transports loads one after the other from the corridor and disposes them in the base of the pigeon-hole and conversely during their removal; said first truck having support wheels at least one of which is driven and a part which can be inserted under the load to lift it, transport it and dispose it; at least a second truck displaceable along the corridor, equipped with a platform which can be brought into position as an extension of the storage surface of the pigeon-holes, on which surface the first truck rolls to pass from the pigeon-hole to the platform and can be brought in front of another pigeon hole or another means for transporting the loads from the entry or taking them towards the exit; the surface of the platform of the second truck being sufficiently large to simultaneously support all the loads which can be placed in one pigeon hole, this platform comprising mechanical transfer means permitting the displacement of the loads along the axis of the corridor, the part of the platform of the second truck on which the first truck rolls, at the exit or at the entry of the pigeonhole, being able to be lowered by a height sufficient to dispose the load transported by the first truck on the transfer mechanism of the second truck and to avoid the first truck forming an obstacle to the longitudinal transfer of the load on the platform.

2. Awarehouse installation in accordance with claim 1, in which the part of the platform of the second truck on which the first truck rolls, at the exit or at the entry of the pigeon-hole, is mounted on a turning abutment and can pivot at least a half turn on itself around a central vertical axis.

3. A warehouse installation in accordance with claim 1, in which the first truck is in the shape of a horseshoe, its two long arms being insertable below the load, each of its arms comprising a support wheel of the truck and at least one lifting surface vertically displaceable by the effect of a mechanism permitting the gentle lifting and lowering of the load.

4. A warehouse installation in accordance with claim 1, in which the mechanical transfer means of the loads on the platform of the second truck comprise rollers, the axis of rotation of which is perpendicular to that of the corridor, said rollers being located in a horizontal plane, disposed adjacent each other to constitute at least one transfer surface on which the displacement of the loads is facilitated.

5. A warehouse installation in accordance with claims 3 and 4, in which the long arms of the first truck have rollers disposed on their upper surfaces, rollers the axes of rotation of which is parallel to the longitudinal axis of the long arm, situated in a horizontal plane, one beside the other to constitute at least one transfer surface on which the displacement of the loads is facilitated, said transfer surface cooperating with that of the second truck to effect the transfer of the loads from the first to the second truck and conversely.

6. A warehouse installation in accordance with claims 3,4 and 5, in which it comprises at least a third truck displaceable along the corridor equipped with a platform, the level of the carrying surface of which corresponds to the level of the corresponding surface of the second truck, this third truck comprising a mechanism permitting the transfer of the loads from this truck to the second one and conversely.

7. A warehouse installation in accordance with claim 6, in which the mechanism permitting the transfer of the loads from the third truck comprises rollers the axes of rotation of which are perpendicu lar to that of the corridor, said rollers being located in a horizontal plane, disposed beside each other to consitute at least one transfer surface on which the displacement of the loads is facilitated.

8. A warehouse installation in accordance with one of claims 4 to 7, in which at least one of the rollers of a transfer surface of the first truck of the second truck;and/or of the third truck is rotated by a motor.

9. A warehouse installation in accordance with one of claims 4 to 8, in which at least two rollers of a transfer surface of the first truck, of the second truck and/or of the third truck are angularly connected to each other via a transmission member, in such a manner that the rotation of one of the rollers drives all of those to which it is connected.

10. Awarehouse installation in accordance with one of claims 1 to 9, comprising several loading surfaces disposed one on top of the other and aligned along the corridor and each surface comprises its own corridor served by at least a second truck and possibly a third truck.

11. A warehouse installation in accordance with one of claims 1 to 9, comprising several loading surfaces disposed one above the other and aligned along the corridor and the second truck is made in the form of a tower displaceable along the corridor in front of the pigeon-holes, this tower carrying the platform which can be brought in front of each pigeon-hole of the warehouse by horizontal displacement of the tower and vertical displacement of the platform.

12. Awarehouse installation in accordance with claim 11, in which the tower comprises a load lifter vertically displacing the loads from the entry level towards the platform of the second truck, respectively from this platform towards the exit.

13. Awarehouse installation substantially as herein described with reference to and as illustrated in the accompanying drawings.