Supports: racks – Endless carrier type – Horizontal travel
Reexamination Certificate
2000-06-08
2002-08-13
Stodola, Daniel P. (Department: 3634)
Supports: racks
Endless carrier type
Horizontal travel
C211S187000
Reexamination Certificate
active
06431376
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to storage systems and more particularly relates to carousel-type storage systems having movable storage bins attached to a frame or track.
2. Brief Description of the Prior Art
Various industries have dedicated considerable time, effort and money to develop large capacity retrieval systems. These storage systems typically comprise a group of movable storage bins that are coupled to a stationary frame. The bins may have an overall height of approximately 30-40 feet. These storage systems are designed to conserve valuable space in a warehouse or factory and facilitate increased productivity since the stored articles can be positioned closer to operators.
One such storage system is disclosed in U.S. Pat. No. 3,368,688, which provides for the storage, transportation and retrieval of documents, file folders and the like. The system includes a plurality of movable storage racks that are coupled to an oblong track, the storage racks being driven on the track by a motor.
In order to increase access to items stored within storage bins, certain preferred embodiments of commonly assigned U.S. Pat. No. 5,207,335 disclose a storage and retrieval system that simultaneously provides access to two side-by-side storage units. Each storage unit has first and second access faces. A first storage portion is accessible from one access face, and a second storage portion is accessible from the opposite access face. A conveyor can be operated so that the first access face of a first bin and the second access face of a second bin confront one another, thereby enabling an operator to simultaneously retrieve articles from both bins.
In certain preferred embodiments of commonly assigned U.S. Pat. No. 5,065,872, the disclosure of which is hereby incorporated by reference herein, a storage, transportation and retrieval system, and accompanying storage racks, are provided for increasing the effective storage capacity of the storage system. The storage system provides for simultaneous access to two adjacent storage racks, thereby requiring less call-ups to locate desired items. The system may be arranged so that it occupies less area.
Referring to
FIG. 1
, the storage and retrieval carousel
10
of the '872 patent is a bottom drive horizontal carousel including a frame structure
12
and a plurality of storage racks
14
moveably connected to the frame structure
12
. Drive mechanism
16
is depicted in a broken away area of
FIG. 1
, as are rollers
18
and guide track
20
. A guide bar
22
facilitates the suspension and/or support of the individual storage racks at the frame structure
12
. The storage racks
14
may be box-like members, which are enclosed on their top, bottom, front and rear sides. Several storage compartments are provided on the sides of each storage rack
14
, thereby providing access to articles stored therein from either side of the storage rack.
Storage racks such as those described above, typically have a substantial vertical height which can be approximately 10-15 feet or higher. The storage rack
14
shown in
FIG. 2A
has an upper end
24
coupled to a movable conveyor
26
and a lower end
28
guided along a path by runners
30
coupled with track
32
.
FIG. 2A
shows the storage bin in a stationary position. When an operator moves the conveyor
26
in order to gain access to one of the storage bins, the conveyor accelerates in a first direction indicated by arrow A
1
, as shown in FIG.
2
B. Due to the substantial height of the. storage bin, and in response to forces exerted upon the bin during movement, the storage bin may buckle or bow. As a result, the buckling or bowing storage bin may contact adjacent bins. Such contact is highly undesirable and may cause damage to the bins or the conveyor system. In order to combat this problem, systems have been designed that provide extra space between adjacent bins to account for buckling. However, the need to provide for extra space between adjacent bins reduces the overall capacity of the storage system.
FIGS. 3A-3C
show another problem encountered when moving storage bins attached to a conveyor system. In
FIG. 3A
, the storage bin is in a stationary position. In
FIG. 3B
, the storage bin is being moved in a direction indicated by arrow A
1
. As the storage bin moves, the upper and lower ends of the bin may twist or turn relative to one another. As shown in
FIG. 3C
, when the conveyor is later decelerated to stop movement of the bins, the bin may twist or turn in the opposite direction. This torsional movement during start-up and stopping of the carousel may ultimately result in permanent deformation of the bins. Such torsional movement may also result in shifting of the items stored in the bins.
Thus, there is a need for a storage system wherein the respective bins have sufficient structural rigidity so as to prevent buckling and/or torsional movement of the bins during start-up and stopping of the carousel. Such a system will allow the respective bins to be positioned closer together, without worrying about adjacent bins contacting each other. Thus, such a system will enable a maximum number of bins to be coupled to the frame, thereby increasing the overall capacity of the system.
SUMMARY OF THE INVENTION
In accordance with certain preferred embodiments of the present invention, a storage bin assembly attachable to a movable carousel-type frame has first and second sidewalls, a backwall and an opening extending along a front face to thereof. The assembly preferably includes a first substantially L-shaped support member including the first sidewall and a first portion of the backwall. The first backwall portion is preferably integrally connected to the first sidewall to form a substantially L-shaped support member having a unitary structure. The assembly also preferably includes a second substantially L-shaped support member including the second sidewall and a second portion of the backwall. The second backwall portion is also preferably integrally connected to the second sidewall to form a substantially L-shaped support member having a unitary structure. During assembly of the storage bin, the first and second support members are preferably configured so that the first and second sidewalls extend in directions that are substantially parallel to one another and the first and second backwall portions extend toward one another. In other words, the inner surfaces of the first and second sidewalls confront one another. In certain preferred embodiments, the first and second portions of the backwall are spaced apart from one another so as to define a longitudinal gap therebetween. The longitudinal gap preferably extends between upper and lower ends of the support members. In other embodiments, the storage bin may be assembled so that the first and second backwall portions engage one another, or overlap with one another.
Each of the first and second support members preferably has an upper end and a lower end. The assembly preferably includes an upper plate secured to the upper ends of the support members and a lower plate secured to the lower ends of the support members. The upper and lower plates preferably enhance the structural integrity of the assembly. The attachment of the upper and lower plates may provide an assembly that does not buckle, bend or twist, as shown and described above. In still other embodiments, a horizontal plate or bar may extend between the first and second sidewalls, at an intermediate point located between the upper and lower ends of the support members. The horizontal plate or bar may add still further structural rigidity to the storage bin assembly.
The first and second sidewalls desirably include front edges remote from the backwall of the assembly and extending between the upper and lower ends of the respective support members. When the storage bin is fully assembled, the front edges of the first and second sidewalls preferably define a front face of the bin assembly. The front edges of the first and s
Harris Erica B.
Lerner David Littenberg Krumholz & Mentlik LLP
Stodola Daniel P.
White Systems, Inc.
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