This invention relates to a storage and retrieval apparatus for small parts and the like. More particularly, this invention relates to a storage and retrieval apparatus for articles such as small parts and the like that is controlled from a remote station.

Systems of automatic storage and retrieval for inventory items to be used in warehouse applications are numerous. All storage and retrieval systems attempt to reduce the time taken in placing inventory items in storage and to reduce the time taken in retrieving the inventory items from storage when desired. Small parts frequently cannot be palletized and often must be stored in bins or containers because of their size or their delicate construction.

Conventional storage and retrieval systems utilize solid storage shelves whereby an extractor or picking mechanism must go to the shelf to pick the desired inventory item. This limits the conventional system to essentially one transaction each time the extractor is operated.

Therefore, it is a principal object and purpose of the present invention to provide a system whereby the desired inventory items are brought to the extractor mechanism as opposed to having the solid shelves where the extractor mechanism must go to the shelf. Combining a single extractor mechanism with a number of independently operating systems to bring the inventory items to the extractor will multiply the speed capabilities of the system.

It is a further object and purpose of the present invention to provide an automatic storage and retrieval system whereby a vacuum pump is utilized to insert containerized inventory items in storage or extract containerized inventory items from storage.

The present invention is designed to place in storage, store, and retrieve small parts and the like automatically upon command from a remote terminal.

A rigid, permanently mounted derrick includes a carriage or shuttle which moves vertically inside the supporting derrick and can accommodate two separate tote bins containing small parts simultaneously. Two sets of carriage roller shuttles are chain driven. Between the two shuttles, two smaller sets of free-floating rollers are aligned. Between the'two sets of free rollers, two tracks contain a travelling arm. Vacuum pump suction rings are mounted on the travelling arm. A tote bin that is positioned on the free rollers can be moved onto either of the roller shuttles through use of sets of chain conveyors on the carriage located between the individual rollers.

The storage and retrieval system includes at least one carousel having a top track and a bottom track. The tracks would be identical, and continuous. The derrick is aligned - adjacent to the carousel.

Each carousel includes a number of compartmented baskets that are parallel to each other and are moved along the tracks by an electrically or hydraulically operated motor.

The multi-faceted system is controlled from a remote digital keyboard operator's terminal. Normally, one tote bin would be taken from storage and another would be returned to storage during each vertical cycle of the carriage. The placement of tote bins in the compartment levels is randomly done through use of a remote laser scanner. The computer memory in the operator's terminal remembers where each tote bin is in the system and will retrieve the desired coded bin upon command.

Reference is made to the accommpanying drawings wherein:-

• ` Figure 1 is a plan view of a small parts storage and retrieval system constructed in accordance with one embodiment of the present invention showing a derrick aligned adjacent to two carousels;
• Figure 2 is a top elevation view of a small parts storage and retrieval system shown in Figure 1;
• Figure 3 is a perspective view of a carriage that would be within the derrick of the small parts storage and retrieval system shown in Figure 1;
• Figure 4 is a plan view of the carriage shown in Figure 3 showing part of the carriage cut-away for clarity;
• Figure 5 is a top elevation view of a small parts storage and-retrieval system constructed in accordance with an alternate embodiment of the present invention;
• Figure 6 is a top elevation view of a travelling arm with suction rings attached that would be located on the carriage shown in Figure 3; and
• Figure 7 is a plan view of the travelling arm and suction rings shown in Figure 6.

Referring to the drawings in detail, Figure 1 through 4 show a system 10 of automatic storage and retrieval for small parts and the like with remote operation. The small parts could be stored in containers or tote bins. The system would be utilized for a multitude of different items, such as car parts, aircraft parts and computer parts and could be used in both retail and wholesale applications.

As best seen in Figure 1, a rigid, permanently mounted derrick 12 is designed for use with small parts storage carousels 14 and 16. A carriage 18 moves vertically inside the supporting derrick 12 and can accommodate two separate containers or tote bins simultaneously. The carriage 18 includes sets of rollers aligned in a horizontal plane. Two vertical poles 20 support the carriage and the carriage is slidably attached thereto. The carriage is moved vertically by an electric motor and weights attached to chain (not shown) would be used as a counter-balance. The feeding of the carriage 18 would be from a waist-high work station or, alternatively, a conveyor 22.

As best seen in Figure 3, two sets of roller shuttles 24 and 26 are attached to a chain drive 28 and remotely operated. Each set of roller shuttles includes a plurality of individual rollers 30. These two sets of roller shuttles would be fed by the work station or the conveyor 22 located near the base of the derrick. In one application of the invention, one shuttle 24 would be used for incoming tote bins while the other shuttle 26 would be used for outgoing tote bins. Guardrails 32 may surround part of the shuttles 24 and 26. Between the two shuttles 24 and 26, two small sets of free rollers 34 and 36 are aligned in the same horizontal plane. Each set of free rollers includes a plurality of individual rollers 38.

Between these sets of free rollers 34 and 36 is a pair of tracks 40 for a travelling arm 42. As seen in Figures _'6 and 7, vacuum pump suction rings. 43 are mounted on the travelling arm. The operation of the travelling arm 42 is remotely controlled. As will be seen, when contact between the travelling arm and the desired container or tote bin has been detected, a vacuum pump (not shown) connected to the rings 43 will be switched on. A tote bin that is positioned on the free-floating rollers 34 and 36 can be moved onto either of the roller shuttles 24 and 26 through sets of chain conveyors 44 and 46. When not in use, the chain conveyors are positioned slightly below the plane of the rollers on the carriage as best seen in Figure 4. Upon command, the chain conveyors 44 and 46 are raised slightly through use of inflatable rubber bladders 48 and 50 located beneath the conveyors.

The system includes at least one storage carousel however, in the preferred embodiment, the storage and retrieval system would include at least two independently operating carousels 14 and 16, mounted one above the other. It is important to note that two independently operating carousels aligned with a single derrick can greatly expedite the working of the system. One carousel could be moving to bring another desired bin to the derrick while the other carousel could be moving to bring another desired bin to the derrick. Thus, as will be seen, the system can accomplish two transactions with each vertical cycle of the carriage.

The structure of each carousel includes a top track 52 and a bottom track 54. The tracks for each carousel would be parallel and identical, oval-like in shape with rounded ends and parallel sides as can be seen in Figure 2. The derrick 12 is aligned adjacent to one of the rounded ends of the carousels.

Each carousel includes a series of compartmented baskets 56, that move along the oval tracks. The baskets 56 are parallel to each other and would be generally perpendicular to the carriage roller sets. The baskets would be lightweight in construction, consisting of wire caging for instance. When in storage, the tote bins 11 would rest in the various compartment levels 58 of the baskets. The tote bins when in storage might protrude slightly from the baskets. The baskets would be moved on the tracks by.an electrically or hydraulically operated motor 60 located on the top track. The baskets in any one carousel would operate independently of the baskets in any other carousel.

The system is multi-faceted and can be made to perform a variety of work chores. The system may be used for "kitting" whereby a series of parts are delivered to a waist-high station to be assembled.

Under normal operating conditions, one tote bin will be taken from storage and another will be returned to storage during each vertical cycle of the carriage 18. The entire operation of the system is contrdlled from a remote digital keyboard operator's terminal (not shown). This computer terminal operates in conjunction with a remote laser scanner (not shown) which is capable of detecting bar codes 61 entered on the outside of the tote bins 11. The code number of the tote bin that is desired to be removed from storage is entered into the terminal. Upon receiving the appropriate command from the operator's terminal, the baskets 56 of one carousel will be moved around the carousel tracks until the appropriate basket is aligned facing the derrick 12.

Meanwhile, the carriage will be moved up from the waist-high work station or conveyor 22. When the carriage has been elevated to the correct height, it will stop, and the travelling arm will move from its resting place until it comes in contact with the desired tote bin. The desired tote bin will be extracted using the vacuum pump suction rings 43 on the travelling arm 42. The computer memory in the-operator's terminal remembers where each tote bin is in the system and will retrieve the desired coded bin upon command. Finally, the tote bin will be moved from the free rollers 34 and 36 to the outgoing shuttle 26 through use of the chain conveyor 46.

After a desired bin has been extracted, another tote bin that has been brought from the work station or conveyor to be placed in storage can be moved from the incoming roller shuttle 24 to the free rollers 34 and 36. The baskets 54 will be moved around the tracks and the carriage 18 will simultaneously move vertically in order to locate an empty compartment. The travelling arm 42 will then move the tote bin from the free rollers 34 and 36 into the empty compartment. The placement of tote bins in the compartment levels is randomly done. The computer memory will "remember" where the tote bin-has been stored in the system.

An advantage of the present invention lies in the improved inventory control that is built into the system. The computer at all times retains an automatic record of the tote bins in the system.

If parts were stored in different size tote bins, the system could be programmed to deliver different size bins to different sized compartments in the baskets.

An alternative embodiment of the invention is shown in Figure 5. A first derrick 62, operating independently of a second derrick 64, would be positioned at the opposite rounded ends. The first derricks 62 could operate to insert bins into the carousels while the second derricks 64 could operate to extract desired bins from the carousels. Independent operation of the derricks 62 and 64 would further increase the speed capabilities of the invention.

The conveyor 66 that feeds the inserter derricks would have a que area 68 which allows incoming tote bins to line up to be inserted in any particular carousel. This would prevent the conveyor system 66 that feeds the derricks 62 from-being backed-up in the event that more than one tote bin is to be inserted in the same carousel.

Whereas the present invention has been described in particular relation to the drawings attached hereto it should be understood that other and further modifications of the invention, apart from those shown or suggested herein, may be made within the spirit and scope of this invention.