System, method and main control system for handling malfunctioning vehicles in an automated storage and retrieval system comprising a rail system
An automated storage and retrieval system includes a rail system with perpendicular tracks in X and Y direction. The storage and retrieval system includes a plurality of remotely operated container handling vehicles configured to move laterally on the rail system; and a main control system using a first communication system for communicating with the plurality of remotely operated container handling vehicles. The main control system monitors and controls the movement of the plurality of container handling vehicles via the first communication system. At least one service vehicle is movable on the rail system. The at least one service vehicle is configured to bring a malfunctioning remotely operated container handling vehicle to a service area outside of the rail system where the remotely operated container handling vehicles operate. The system further includes a secondary control system using a second communication system. The second communication system is independent of the main communication system. The secondary control system is communicating with the at least one service vehicle on the rail system such as to monitor and control the movement of the at least one service vehicle.
1. An automated storage and retrieval system comprising a rail system with perpendicular tracks in X and Y directions, wherein the automated storage and retrieval system comprises:
a plurality of remotely operated container handling vehicles configured to move laterally on the rail system;
a main control system using a first communication system for communicating with the plurality of remotely operated container handling vehicles, wherein the main control system monitors and controls movement of the plurality of remotely operated container handling vehicles via the first communication system;
at least one service vehicle movable on the rail system, wherein the at least one service vehicle is configured to bring a malfunctioning remotely operated container handling vehicle to a service area outside of the rail system where the plurality of remotely operated container handling vehicles operate; and
a secondary control system using a second communication system, wherein the second communication system is independent of the first communication system, and wherein the secondary control system is communicating with the at least one service vehicle on the rail system such as to monitor and control the movement of the at least one service vehicle;
wherein the main control system is configured to perform, by wireless data communication, at least:
determining an anomaly in an operational condition of a remotely operated container handling vehicle on the rail system,
registering the remotely operated container handling vehicle with the anomalous operational condition as a malfunctioning remotely operated container handling vehicle,
registering a position of the malfunctioning remotely operated container handling vehicle relative to the rail system, and
setting up a two-dimensional exclusion zone extending from the malfunctioning remotely operated container handling vehicle to a position of the at least one service vehicle.
2. The automated storage and retrieval system according to claim 1 , wherein the main control system is further configured to perform:
updating a movement pattern of the plurality of remotely operated container handling vehicles by instructing any remotely operated container handling vehicles positioned within the two-dimensional exclusion zone to move outside the two-dimensional exclusion zone and avoiding entry of any of remaining remotely operated container handling vehicles into the two-dimensional exclusion zone.
3. The automated storage and retrieval system according to claim 2 , wherein, the secondary control system is configured to perform, by the wireless data communication:
operating the at least one service vehicle to move from an initial position to a position next to the malfunctioning remotely operated container handling vehicle along the two-dimensional exclusion zone.
4. The automated storage and retrieval system according to claim 1 , wherein the first communication system and the second communication system are the same communication system or different communication systems.
5. The automated storage and retrieval system according to claim 4 , wherein the first communication system and the second communication system operate with different frequencies.
6. The automated storage and retrieval system according to claim 4 , wherein the first communication system and the second communication system have different coding and de-coding processes.
7. The automated storage and retrieval system according to claim 1 , wherein the first communication system comprises wireless fidelity (WiFi) and the second communication system comprises light fidelity (LiFi).
8. The automated storage and retrieval system according to claim 1 , wherein the at least one service vehicle comprises wheels which are guided for movement along the rail system in the X and Y directions.
9. The automated storage and retrieval system according to claim 1 , wherein the at least one service vehicle comprises caterpillar tracks for movement over a top surface of the rail system independent of the X and Y directions of the rail system.
10. The automated storage and retrieval system according to claim 1 , wherein an initial position of the at least one service vehicle is in a service area outside of the rail system where the plurality of remotely operated container handling vehicles operate.
11. The automated storage and retrieval system according to claim 1 , wherein the rail system is at a top level of a storage grid.
12. The automated storage and retrieval system according to claim 1 , wherein the rail system is a delivery rail system.
13. A method for handling malfunctioning vehicles on a rail system associated with a storage and retrieval system, wherein the storage and retrieval system comprises:
a plurality of remotely operated container handling vehicles configured to move laterally on the rail system;
a main control system using a first communication system for communicating with the plurality of remotely operated container handling vehicles wirelessly, wherein the main control system monitors and controls movement of the plurality of remotely operated container handling vehicles via the first communication system;
at least one service vehicle positioned at an initial position, wherein the at least one service vehicle is movable on the rail system, and wherein the at least one service vehicle is configured to bring a malfunctioning remotely operated container handling vehicle to a service area outside of the rail system where the plurality of remotely operated container handling vehicles operate;
a secondary control system, using a second communication system which is independent of the first communication system for communicating with the at least one service vehicle on the rail system wirelessly, and wherein the secondary control system monitors and controls the movement of the at least one service vehicle;
the main control system performs at least:
determining an anomaly in an operational condition of a remotely operated container handling vehicle on the rail system,
registering the remotely operated container handling vehicle with the anomalous operational condition as a malfunctioning remotely operated container handling vehicle,
registering a position of the malfunctioning remotely operated container handling vehicle relative to the rail system, and
setting up a two-dimensional exclusion zone extending from the malfunctioning remotely operated container handling vehicle to the position of the at least one service vehicle.
14. The method according to claim 13 , wherein the method further comprises utilizing the main control system to:
update a movement pattern of the plurality of remotely operated container handling vehicles outside the two-dimensional exclusion zone such that entrance into the two-dimensional exclusion zone is avoided.
15. The method according to claim 14 , wherein the method further comprises the secondary control system performing
operating the at least one service vehicle to move from the initial position to the position where the malfunctioning remotely operated container handling vehicle is halted along the two-dimensional exclusion zone.
16. A main control system for an automated storage and retrieval system, the automated storage and retrieval system comprising:
a rail system with horizontal tracks extending in perpendicular X and Y directions;
a plurality of remotely operated container handling vehicles configured to operate on the rail system;
at least one service vehicle; and
a secondary control system for the at least one service vehicle, wherein the secondary control system is communicating with the at least one service vehicle on the rail system such as to monitor and control movement of the at least one service vehicle, and wherein the at least one service vehicle is configured to bring a malfunctioning remotely operated container handling vehicle to a service area outside of the rail system where the plurality of remotely operated container handling vehicles operate,
wherein the main control system is configured to route the plurality of remotely operated container handling vehicles across a working zone of the rail system, the main control system further being configured to detect if a remotely operated container handling vehicle is malfunctioning, and if the remotely operated container handling vehicle is malfunctioning, the main control system being configured to:
reconfigure the working zone to divide off an exclusion zone, the exclusion zone defining an area of the rail system containing the malfunctioning remotely operated container handling vehicle and providing a path for the at least one service vehicle to reach the malfunctioning remotely operated container handling vehicle;
reroute other remotely operated container handling vehicles operating in the exclusion zone and in the reconfigured working zone so that they avoid the area of the rail system defined by the exclusion zone; and
hand over control of the area of the rail system in the exclusion zone to the secondary control system.
17. The main control system according to claim 16 , wherein the main control system is configured, once the at least one service vehicle has moved out of the exclusion zone of the rail system, to:
take back control of the area of the rail system within the exclusion zone from the secondary control system;
reconfigure the working zone to include the area of the rail system that was previously in the exclusion zone; and
reroute remotely operated container handling vehicles to take account of the reconfigured working zone having the area of the rail system that was previously in the exclusion zone being included as part of the working zone.