Storage and retrieval system.
Abstract
Se proporcionan un sistema y un método para almacenar y recuperar. El sistema incluye una estructura de almacenamiento de múltiples niveles, y robots móviles configurados para recoger, transportar y colocar uno o más recipientes, contenedores u objetos. Este sistema y método pueden ser usados en aplicaciones de cumplimiento de órdenes en las cuales una o más estaciones de trabajo acomodan un recogedor que transporta uno o más artículos ocultos de un recipiente sobre uno de los robots móviles autónomos a un lugar de ubicación y una interfaz de entrada/salida que induce el material hacia el sistema y descarga las órdenes cumplidas del sistema. Los robots móviles están configurados además para desplazarse de nivel a nivel en la estructura de almacenamiento de múltiples niveles vía carriles inclinados o verticales sin requerir una transportadora de elevación vertical o vertical.

Term
11.2 yearsleft in the term
Expires 30 November 2037.
- Priority
- Filed
- Granted
- Today
- Expires
37 claims: 7 independent, 30 dependent
- 1Un sistema de entrega de pedidos, que comprende:una cubierta;una estructura de estantería de múltiples niveles configurada para almacenar cestas, la estructura de estantería de múltiples niveles comprende: primera y segunda estanterías de múltiples niveles separadas por un pasillo, un par de rieles horizontales separados entre sí a través del pasillo, un eje de desplazamiento que se defina lo largo del par de rieles horizontales, y un par de carriles verticales separados entre sí a través del pasillo, los carriles verticales interconectan niveles de la estructura de estantería de múltiples niveles, cada uno del par de carriles comprende una estantería de dientes, los dientes en cada estantería orientados a lo largo del eje de desplazamiento, y cada uno del par de rieles horizontales incluye una separación alineada con los carriles verticales;y un robot móvil, que comprende: un primer eje;un primer par de ruedas en lados opuestos del robot móvil adyacentes a un primer extremo del robot móvil, el primer par de ruedas montadas para rotar y moverse axialmente, al menos una rueda de la primera y segunda ruedas montada en el primer eje;un segundo par de ruedas en los lados opuestos del robot móvil adyacentes a un segundo extremo del robot móvil, el segundo par de ruedas montadas para rotar y moverse axialmente;un montaje giratorio de rueda en una parte inferior del robot móvil entre los lados opuestos del robot móvil, en donde el primer y segundo pares de ruedas están configurados para guiar el robot móvil a lo largo del eje de desplazamiento en los rieles, y el primer par de ruedas y el montaje giratorio de rueda están configurados para maniobrar el robot móvil en la cubierta;un segundo eje paralelo a y separado del primer eje;un piñón en un lado de los lados opuestos del robot móvil, el piñón montado para rotar y moverse axialmente, el piñón configurado para acoplarse a una estantería de dientes en un carril del par de carriles para mover el robot móvil verticalmente, el piñón montado en el segundo eje, en donde el segundo eje está configurado para extenderse a través de la separación en uno de los rieles horizontales a medida que el robot móvil se mueve verticalmente a lo largo del par de carriles, y en donde el piñón está configurado para contactar y acoplarse con la estantería de dientes en el carril cuando se mueve axialmente;un contrafuerte en el segundo eje, el piñón montado para rotar y moverse axialmente, el contrafuerte configurado para mantener el acoplamiento entre el piñón y el carril;απηπ Ln/zznz/E/YiAi el primer par de ruedas, el segundo par de ruedas, el piñón y el contrafuerte configurados para moverse axialmente en una pluralidad de posiciones relativas entre sí, la pluralidad de posiciones comprenden: una primera posición, donde el primer y segundo pares de ruedas se extienden axialmente, y el piñón y el contrafuerte se retraen axialmente, una segunda posición, donde el primer y segundo pares de ruedas se extienden axialmente, y el piñón y el contrafuerte se extienden axial mente, y una tercera posición, donde el primer y segundo pares de ruedas se retraen axialmente, y el piñón y el contrafuerte se extienden axialmente.
- 2El sistema de entrega de pedidos de acuerdo con la reivindicación 1, en donde, en la primera posición, el robot móvil está configurado para moverse horizontalmente a lo largo de los rieles y cubierta.
- 3El sistema de entrega de pedidos de acuerdo con la reivindicación 1, en donde, en la segunda posición, el robot móvil está siendo transición entre el movimiento horizontal a lo largo de los rieles y el movimiento vertical a lo largo del carril.
- 4El sistema de entrega de pedidos de acuerdo con la reivindicación 1, en donde, en la tercera posición, el robot móvil está configurado para moverse verticalmente a lo largo del carril.
- 5El sistema de entrega de pedidos de acuerdo con la reivindicación 1, que comprende además un mecanismo de transferencia de cestas para transferir cestas entre el robot móvil y una ubicación de almacenamiento de la primera y segunda estanterías de múltiples niveles.
- 6El sistema de entrega de pedidos de acuerdo con la reivindicación 5, en donde el mecanismo de transferencia de cestas está configurado para extenderse hacia la primera estantería de múltiples niveles y hacia la segunda estantería de múltiples niveles.
- 7El sistema de entrega de pedidos de acuerdo con la reivindicación 1, en donde el carril incluye primera, segunda y tercera superficies, la primera y tercera superficies orientadas en direcciones opuestas a lo largo del eje de desplazamiento, en donde la estantería de dientes está montada en la primera superficie.
- 8El sistema de entrega de pedidos de acuerdo con la reivindicación 7, en donde el contrafuerte se apoya contra la tercera superficie del carril.
- 9El robot móvil de acuerdo con la reivindicación 1, en donde el contrafuerte está configurado para mantener el acoplamiento entre el piñón y la estantería de dientes al establecer una profundidad de acoplamiento del piñón con la estantería de dientes.
- 10El robot móvil de acuerdo con la reivindicación 1, que comprende además un cambio en una intersección entre un riel horizontal y un carril vertical en un lado del pasillo, el cambio configurado para afectar el desplazamiento vertical del robot móvil en el carril o desplazamiento horizontal del robot móvil en el riel, απηπ ίη/ζζηζ/Ε/γίΛΐ dependiendo de una posición del cambio.
- 11Un sistema de entrega de pedidos, que comprende:una cubierta;una estructura de estantería de múltiples niveles configurada para almacenar cestas, la estructura de estantería de múltiples niveles comprende: primera y segunda estanterías de múltiples niveles separadas por un pasillo, un par de rieles horizontales separados entre sí a través del pasillo, un eje de desplazamiento que se defina lo largo del par de rieles horizontales, y un par de carriles verticales separados entre sí a través del pasillo, los carriles verticales interconectan niveles de la estructura de estantería de múltiples niveles, cada uno del par de carriles comprende una estantería de dientes, y cada uno del par de rieles horizontales incluye una separación alineada con los carriles verticales;y un robot móvil, que comprende: un primer eje;un primer par de ruedas en lados opuestos del robot móvil adyacentes a un primer extremo del robot móvil, el primer par de ruedas montadas para rotar y moverse axialmente, al menos una rueda de la primera y segunda ruedas montada en el primer eje;un segundo par de ruedas en los lados opuestos del robot móvil adyacentes a un segundo extremo del robot móvil, el segundo par de ruedas montadas para rotar y moverse axialmente;un montaje giratorio de rueda en una parte inferior del robot móvil entre los lados opuestos del robot móvil, en donde el primer y segundo pares de ruedas están configurados para guiar el robot móvil a lo largo del eje de desplazamiento en los rieles, y el primer par de ruedas y el montaje giratorio de rueda están configurados para maniobrar el robot móvil en la cubierta;un segundo eje paralelo a y separado del primer eje;un piñón en un lado de los lados opuestos del robot móvil, el piñón montado para rotar y moverse axialmente, el piñón configurado para acoplarse a una estantería de dientes en un carril del par de carriles para mover el robot móvil verticalmente, el piñón montado en el segundo eje, en donde el segundo eje está configurado para extenderse a través de la separación en uno de los rieles horizontales a medida que el robot móvil se mueve verticalmente a lo largo del par de carriles, y en donde el piñón está configurado para contactar y acoplarse con la estantería de dientes en el carril cuando se mueve axialmente;un contrafuerte en el segundo eje, el piñón montado para rotar y moverse axialmente, el contrafuerte configurado para mantener el acoplamiento entre el piñón y el carril;απηπ ίη/ζζηζ/Ε/γίΛΐ el primer par de ruedas, el segundo par de ruedas, el piñón y el contrafuerte configurados para moverse axialmente en una pluralidad de posiciones relativas entre sí, la pluralidad de posiciones comprenden: una primera posición, donde el primer y segundo pares de ruedas se extienden axialmente, y el piñón y el contrafuerte se retraen axialmente, una segunda posición, donde el primer y segundo pares de ruedas se extienden axialmente, y el piñón y el contrafuerte se extienden axial mente, y una tercera posición, donde el primer y segundo pares de ruedas se retraen axialmente, y el piñón y el contrafuerte se extienden axialmente.
- 12El sistema de entrega de pedidos de acuerdo con la reivindicación 11, en donde el carril incluye primera, segunda y tercera superficies, la primera y tercera superficies orientadas en direcciones opuestas a lo largo del eje de desplazamiento, en donde la estantería de dientes está montada en la primera superficie.
- 13El sistema de entrega de pedidos de acuerdo con la reivindicación 12, en donde el contrafuerte se apoya contra la tercera superficie del carril.
- 14El robot móvil de acuerdo con la reivindicación 11, en donde el contrafuerte está configurado para mantener el acoplamiento entre el piñón y la estantería de dientes al establecer una profundidad de acoplamiento del piñón con la estantería de dientes.
- 15Un sistema de entrega de pedidos, que comprende:una cubierta;una estructura de estantería de múltiples niveles configurada para almacenar cestas, la estructura de estantería de múltiples niveles comprende: primera y segunda estanterías de múltiples niveles separadas por un pasillo, un par de rieles horizontales separados entre sí a través del pasillo, un eje de desplazamiento que se defina lo largo del par de rieles horizontales, y un par de carriles verticales separados entre sí a través del pasillo, los carriles verticales interconectan niveles de la estructura de estantería de múltiples niveles, cada uno del par de carriles comprende una estantería de dientes, los dientes en cada estantería orientados a lo largo del eje de desplazamiento, y cada uno del par de rieles horizontales incluye una separación alineada con los carriles verticales;y un robot móvil, que comprende: un primer eje;un primer par de ruedas en lados opuestos del robot móvil adyacentes a un primer extremo del robot móvil, el primer par de ruedas montadas para rotar y moverse axialmente, al menos una rueda de la primera y segunda ruedas montada en el primer eje;απηπ Ln/zznz/E/YiAi un segundo par de ruedas en los lados opuestos del robot móvil adyacentes a un segundo extremo del robot móvil, el segundo par de ruedas montadas para rotar y moverse axialmente;un montaje giratorio de rueda en una parte inferior del robot móvil entre los lados opuestos del robot móvil, en donde el primer y segundo pares de ruedas están configurados para guiar el robot móvil a lo largo del eje de desplazamiento en los rieles, y el primer par de ruedas y el montaje giratorio de rueda están configurados para maniobrar el robot móvil en la cubierta;un segundo eje separado del primer eje;un piñón en un lado de los lados opuestos del robot móvil, el piñón montado para rotar y moverse axialmente, el piñón configurado para acoplarse a una estantería de dientes en un carril del par de carriles para mover el robot móvil verticalmente, el piñón montado en el segundo eje, en donde el segundo eje está configurado para extenderse a través de la separación en uno de los rieles horizontales a medida que el robot móvil se mueve verticalmente a lo largo del par de carriles, y en donde el piñón está configurado para contactar y acoplarse con la estantería de dientes en el carril cuando se mueve axialmente;un contrafuerte en el segundo eje, el piñón montado para rotar y moverse axialmente, el contrafuerte configurado para mantener el acoplamiento entre el piñón y el carril;el primer par de ruedas, el segundo par de ruedas, el piñón y el contrafuerte configurados para moverse axialmente en una pluralidad de posiciones relativas entre sí, la pluralidad de posiciones comprenden: una primera posición, donde el primer y segundo pares de ruedas se extienden axialmente, y el piñón y el contrafuerte se retraen axialmente, una segunda posición, donde el primer y segundo pares de ruedas se extienden axialmente, y el piñón y el contrafuerte se extienden axialmente, y una tercera posición, donde el primer y segundo pares de ruedas se retraen axialmente, y el piñón y el contrafuerte se extienden axialmente.
- 16El sistema de entrega de pedidos de acuerdo con la reivindicación 15, en donde el carril incluye primera, segunda y tercera superficies, la primera y tercera superficies orientadas en direcciones opuestas a lo largo del eje de desplazamiento, en donde la estantería de dientes está montada en la primera superficie.
- 17El sistema de entrega de pedidos de acuerdo con la reivindicación 16, en donde el contrafuerte se apoya contra la tercera superficie del carril.
- 18El robot móvil de acuerdo con la reivindicación 15, en donde el contrafuerte está configurado para mantener el acoplamiento entre el piñón y la estantería de dientes al establecer una profundidad de acoplamiento del piñón con la estantería de dientes.
- 19Un sistema de entrega de pedidos, que comprende:απηπ ίη/ζζηζ/Ε/γίΛΐ una cubierta;una estructura de estantería de múltiples niveles configurada para almacenar cestas, la estructura de estantería de múltiples niveles comprende: primera y segunda estanterías de múltiples niveles separadas por un pasillo, un par de rieles horizontales separados entre sí a través del pasillo, un eje de desplazamiento que se defina lo largo del par de rieles horizontales, y un par de carriles verticales separados entre sí a través del pasillo, los carriles verticales interconectan niveles de la estructura de estantería de múltiples niveles, cada uno del par de carriles comprende una estantería de dientes, los dientes en cada estantería orientados a lo largo del eje de desplazamiento, y cada uno del par de rieles horizontales incluye una separación alineada con los carriles verticales;y un robot móvil, que comprende: un primer eje;un primer par de ruedas en lados opuestos del robot móvil adyacentes a un primer extremo del robot móvil, el primer par de ruedas montadas para rotar y moverse axialmente, al menos una rueda de la primera y segunda ruedas montada en el primer eje;un segundo par de ruedas en los lados opuestos del robot móvil adyacentes a un segundo extremo del robot móvil, el segundo par de ruedas montadas para rotar y moverse axialmente;un montaje giratorio de rueda en una parte inferior del robot móvil entre los lados opuestos del robot móvil, en donde el primer y segundo pares de ruedas están configurados para guiar el robot móvil a lo largo del eje de desplazamiento en los rieles, y el primer par de ruedas y el montaje giratorio de rueda están configurados para maniobrar el robot móvil en la cubierta;un segundo eje paralelo a y separado del primer eje;un piñón en un lado de los lados opuestos del robot móvil, el piñón montado para rotar y moverse axialmente, el piñón configurado para acoplarse a una estantería de dientes en un carril del par de carriles para mover el robot móvil verticalmente, el piñón montado en el segundo eje, en donde el segundo eje está configurado para extenderse a través de la separación en uno de los rieles horizontales a medida que el robot móvil se mueve verticalmente a lo largo del par de carriles, y en donde el piñón está configurado para contactar y acoplarse con la estantería de dientes en el carril cuando se mueve axialmente;el primer par de ruedas, el segundo par de ruedas y el piñón configurados para moverse axialmente en una pluralidad de posiciones relativas entre sí, la pluralidad de posiciones comprenden: una primera posición, donde el primer y segundo pares de ruedas se extienden axialmente, y el piñón se retrae axialmente, απηπ Ln/zznz/E/YiAi una segunda posición, donde el primer y segundo pares de ruedas se extienden axialmente, y el piñón se extiende axialmente, y una tercera posición, donde el primer y segundo pares de ruedas se retraen axialmente, y el piñón se extiende axialmente.
- 20El sistema de entrega de pedidos de acuerdo con la reivindicación 19, en donde el carril incluye primera, segunda y tercera superficies, la primera y tercera superficies orientadas en direcciones opuestas a lo largo del eje de desplazamiento, en donde la estantería de dientes está montada en la primera superficie.
- 21El sistema de entrega de pedidos de acuerdo con la reivindicación 20, en donde el contrafuerte se apoya contra la tercera superficie del carril.
- 22El robot móvil de acuerdo con la reivindicación 19, en donde el contrafuerte está configurado para mantener el acoplamiento entre el piñón y la estantería de dientes al establecer una profundidad de acoplamiento del piñón con la estantería de dientes.
- 23Un sistema de entrega de pedidos, que comprende:una cubierta;una estructura de estantería de múltiples niveles configurada para almacenar cestas, la estructura de estantería de múltiples niveles comprende: primera y segunda estanterías de múltiples niveles separadas por un pasillo, un par de rieles horizontales separados entre sí a través del pasillo, un eje de desplazamiento que se defina lo largo del par de rieles horizontales, y un par de carriles verticales separados entre sí a través del pasillo, los carriles verticales interconectan niveles de la estructura de estantería de múltiples niveles, cada uno del par de carriles comprende una estantería de dientes, los dientes en cada estantería orientados a lo largo del eje de desplazamiento, y cada uno del par de rieles horizontales incluye una separación alineada con los carriles verticales;y un robot móvil, que comprende: un primer eje;un primer par de ruedas en lados opuestos del robot móvil adyacentes a un primer extremo del robot móvil, el primer par de ruedas montadas para rotar y moverse axialmente, al menos una rueda de la primera y segunda ruedas montada en el primer eje;un segundo par de ruedas en los lados opuestos del robot móvil adyacentes a un segundo extremo del robot móvil, el segundo par de ruedas montadas para rotar y moverse axialmente;un montaje giratorio de rueda en una parte inferior del robot móvil entre los lados opuestos del robot móvil, en donde el primer y segundo pares de ruedas están configurados para guiar el robot móvil a lo απηπ Ln/zznz/E/YiAi largo del eje de desplazamiento en los rieles, y el primer par de ruedas y el montaje giratorio de rueda están configurados para maniobrar el robot móvil en la cubierta;un segundo eje paralelo a y separado del primer eje;un piñón en un lado de los lados opuestos del robot móvil, el piñón montado para rotar y moverse axialmente, el piñón configurado para acoplarse a una estantería de dientes en un carril del par de carriles para mover el robot móvil verticalmente, el piñón montado en el segundo eje, en donde el segundo eje está configurado para extenderse a través de la separación en uno de los rieles horizontales a medida que el robot móvil se mueve verticalmente a lo largo del par de carriles, y en donde el piñón está configurado para contactar y acoplarse con la estantería de dientes en el carril cuando se mueve axialmente;y un contrafuerte en el segundo eje, el piñón montado para rotar y moverse axialmente, el contrafuerte configurado para mantener el acoplamiento entre el piñón y el carril.
- 24El sistema de entrega de pedidos de acuerdo con la reivindicación 23, en donde el carril incluye primera, segunda y tercera superficies, la primera y tercera superficies orientadas en direcciones opuestas a lo largo del eje de desplazamiento, en donde la estantería de dientes está montada en la primera superficie.
- 25El sistema de entrega de pedidos de acuerdo con la reivindicación 24, en donde el contrafuerte se apoya contra la tercera superficie del carril.
- 26El robot móvil de acuerdo con la reivindicación 23, en donde el contrafuerte está configurado para mantener el acoplamiento entre el piñón y la estantería de dientes al establecer una profundidad de acoplamiento del piñón con la estantería de dientes.
- 27Un robot móvil para desplazarse sobre una cubierta y dentro de una estructura de estantería de múltiples niveles para transferir cestas hacia y desde la estructura de estantería de múltiples niveles, la estructura de estantería de múltiples niveles comprende un par de rieles horizontales separados y un par de carriles verticales separados, el robot móvil comprende:un primer par de ruedas en lados opuestos del robot móvil adyacentes a un primer extremo del robot móvil, el primer par de ruedas montadas para rotar y moverse axialmente, al menos una rueda de la primera y segunda ruedas montada en un primer eje;un segundo par de ruedas en los lados opuestos del robot móvil adyacentes a un segundo extremo del robot móvil, el segundo par de ruedas montadas para rotar y moverse axialmente;un montaje giratorio de rueda en una parte inferior del robot móvil entre los lados opuestos del robot móvil, en donde el primer y segundo pares de ruedas están configurados para guiar el robot móvil a lo largo de los rieles horizontales, y el primer par de ruedas y el montaje giratorio de rueda están configurados para maniobrar el robot móvil en la cubierta;απηπ Ln/zznz/E/YiAi un piñón en un lado de los lados opuestos del robot móvil, el piñón montado para rotar y moverse axialmente, el piñón configurado para acoplarse a los carriles verticales para mover el robot móvil verticalmente, el piñón montado en un segundo eje, en donde el segundo eje es paralelo a y está separado del primer eje, y en donde el piñón está configurado para contactar un carril del par de carriles cuando se mueve axialmente;un contrafuerte en el segundo eje, el piñón montado para rotar y moverse axialmente, el contrafuerte configurado para mantener el acoplamiento entre el piñón y el carril;el primer par de ruedas, el segundo par de ruedas, el piñón y el contrafuerte configurados para moverse axialmente en una pluralidad de posiciones relativas entre sí, la pluralidad de posiciones comprenden: una primera posición, donde el primer y segundo pares de ruedas se extienden axialmente, y el piñón y el contrafuerte se retraen axialmente, una segunda posición, donde el primer y segundo pares de ruedas se extienden axialmente, y el piñón y el contrafuerte se extienden axialmente, y una tercera posición, donde el primer y segundo pares de ruedas se retraen axialmente, y el piñón y el contrafuerte se extienden axialmente.
- 28El robot móvil de acuerdo con la reivindicación 27, en donde, en la primera posición, el robot móvil está configurado para moverse horizontalmente a lo largo de los rieles horizontales y cubierta.
- 29El robot móvil de acuerdo con la reivindicación 27, en donde, en la segunda posición, el robot móvil está siendo transición entre el movimiento horizontal a lo largo de los rieles horizontales y el movimiento vertical a lo largo del carril.
- 30El robot móvil de acuerdo con la reivindicación 27, en donde, en la tercera posición, el robot móvil está configurado para moverse verticalmente a lo largo del carril.
- 31El robot móvil de acuerdo con la reivindicación 27, que comprende además un mecanismo de transferencia de cestas para transferir cestas entre el robot móvil y una ubicación de almacenamiento de la estructura de estantería de múltiples niveles.
- 32El robot móvil de acuerdo con la reivindicación 31, en donde la estructura de estantería de múltiples niveles comprende primera y segunda estructuras de estantería separadas a través de un pasillo, en donde el mecanismo de transferencia de cestas está configurado para extenderse hacia la primera estantería de múltiples niveles y hacia la segunda estantería de múltiples niveles.
- 33El robot móvil de acuerdo con la reivindicación 27, que comprende además un primer motor para accionar el primer par de ruedas.
- 34El robot móvil de acuerdo con la reivindicación 33, que comprende además un segundo motor para accionar el piñón. απηπ Ln/zznz/E/YiAi
- 3538. El robot móvil de acuerdo con la reivindicación 37, en donde el carril comprende una estantería, y en donde el contrafuerte está configurado para mantener el acoplamiento entre el piñón y la estantería al establecer una profundidad de acoplamiento del piñón con la estantería.
- 3639. Un robot móvil para desplazarse sobre una cubierta y dentro de una estructura de estantería de múltiples niveles para transferir cestas hacia y desde la estructura de estantería de múltiples niveles, la estructura de estantería de múltiples niveles comprende un par de rieles horizontales separados y un par de carriles verticales separados, el robot móvil comprende:un primer par de ruedas en lados opuestos del robot móvil adyacentes a un primer extremo del robot móvil, el primer par de ruedas montadas para rotar y moverse axialmente, al menos una rueda de la primera y segunda ruedas montada en un primer eje;un segundo par de ruedas en los lados opuestos del robot móvil adyacentes a un segundo extremo del robot móvil, el segundo par de ruedas montadas para rotar y moverse axialmente;un montaje giratorio de rueda en una parte inferior del robot móvil entre los lados opuestos del robot móvil, en donde el primer y segundo pares de ruedas están configurados para guiar el robot móvil a lo largo de los rieles horizontales, y el primer par de ruedas y el montaje giratorio de rueda están configurados para maniobrar el robot móvil en la cubierta;un piñón en un lado de los lados opuestos del robot móvil, el piñón montado para rotar y moverse axialmente, el piñón configurado para acoplarse a los carriles verticales para mover el robot móvil verticalmente, el piñón montado en un segundo eje, en donde el segundo eje es paralelo a y está separado del primer eje, y en donde el piñón está configurado para contactar un carril del par de carriles cuando se mueve axialmente;y un contrafuerte en el segundo eje, el piñón montado para rotar y moverse axialmente, el contrafuerte configurado para mantener el acoplamiento entre el piñón y el carril.
- 3740. El robot móvil de acuerdo con la reivindicación 39, en donde el carril comprende una estantería, y en donde el contrafuerte está configurado para mantener el acoplamiento entre el piñón y la cremallera al establecer una profundidad de acoplamiento del piñón con la cremallera.
Independent claims37
287 paragraphs in 7 sections, as filed
STORAGE AND RECOVERY SYSTEM
FIELD OF THE INVENTION
The exemplary and non-limiting embodiments described herein relate generally to a storage and retrieval system, and more particularly to an order fulfillment system for use in supply chains according to an illustrative embodiment.
BACKGROUND OF THE INVENTION
The storage and retrieval of objects is a process that is carried out in many ways for many purposes. One specific use of storage and retrieval, that is, order fulfillment, is a central process carried out within virtually all supply chains, especially retail supply chains. Manufacturers typically store and retrieve pallets containing boxes of products within their layouts to fulfill product orders placed by retailers. Retailers store and retrieve both cases and individual items, or “pieces,” within their own distribution centers to deliver orders placed by their stores in per-case quantities and smaller than case quantities of products. Increasingly, with the rise of e-commerce, retailers are also faced with the need to deliver piece-meal orders placed directly by individual consumers.
Conventional order fulfillment processes within retail distribution centers use manual storage and retrieval systems and methods in which boxes or baskets containing parts are stored in stationary locations and carried by human delivery drivers to selected locations to collect the parts. boxes or pieces requested, respectively. However, the work efficiency of these “product picker” processes is typically low because delivery drivers spend much more time traveling to locations than actually collecting the ordered items.
The most successful solutions to improve work efficiency in order fulfillment processes use some forms of an automated storage and retrieval system and method in a “products to the picker” process in which baskets are delivered by mechanized means to a workstation, where a picker (human or robotic) places boxes on pallets for delivery to stores or transfers pieces from product baskets to order baskets for delivery to stores or individual customers.
BRIEF DESCRIPTION OF THE INVENTION
There is a need for an automated storage and retrieval system, such as could be implemented by an order fulfillment system among other implementations, that is highly cheap and effective in units per order line and order lines per SKU, but that Provide design flexibility that allows the configuration to be optimized for the application based on operating metrics. The present invention is directed to additional solutions to solve this need, in addition to having other desirable characteristics. Specifically, a storage and retrieval system is provided. According to an exemplary embodiment used to demonstrate the utility of the storage and retrieval system, an order delivery system includes a basket storage structure that stores baskets and supports the operation of mobile robots in he. Mobile robots move in three dimensions: horizontally (forward, backward, left and right) on flat transit decks that interconnect support structures and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level basket storage structure 32. Picking Workstations are arranged at multiple elevations where human or robotic pickers remove hidden items from product baskets and place them into order baskets or a mobile robot, depending on the configuration. A central control system includes software, computers, and network equipment. The central control system manages system resources. An input/output interface supplies baskets entering the system and discharges baskets leaving the system.
The following brief description is only intended to be exemplary. The brief description is not intended to limit the scope of the claims. Specifically, the invention is directed to an automated storage and retrieval system. The system may well be used in the illustrative role of an order delivery system as described herein, but is not limited to order delivery. Instead, the system and method of the present invention can be used as a general article or object storage and retrieval system, as would be appreciated by one skilled in the art with the benefit of the description and Figures described herein.
According to an exemplary embodiment of the present invention, a mobile robot includes one or more horizontal actuators that drive the mobile robot in at least one direction along at least two horizontal directions. One or more vertical actuators drive the mobile robot in at least one direction along at least one vertical dimension. One or more horizontal actuators are configured to engage with horizontal rails of a multi-level storage structure, and one or more vertical actuators are configured to engage with inclined or vertical rails of the multi-level storage structure. The mobile robot is configured to propel itself horizontally along levels of the multi-level storage structure, and to propel itself vertically from level to level of the multi-level storage structure using the inclined or vertical rails. of the multi-level storage structure while maintaining a horizontal posture.
In accordance with aspects of the present invention, the mobile robot may further include a drive shaft to which one or more horizontal actuators and one or more vertical actuators are coupled. The drive shaft may be extendable and retractable to selectively engage or disengage one or more horizontal actuators and one or more vertical actuators with a desired rail of a horizontal orientation, or with a desired rail of an inclined or vertical orientation. The drive shaft may be extendable or retractable to selectively engage or disengage one or more horizontal actuators and one or more vertical actuators with a desired rail of a horizontal orientation, or with a desired rail of an inclined orientation or vertical orientation, such as to allow the mobile robot to select a desired lane from the horizontal orientation or a desired lane from the inclined or vertical orientation without requiring an active lane change.
In accordance with aspects of the present invention, one or more horizontal actuators may include one or more wheels. One or more vertical actuators may include one or more gear wheels. A Basket transfer mechanism may be arranged on a frame of the mobile robot. The mobile robot can be configured to be in communication and receive control orders from a centralized control system. The mobile robot may include an on-board control computer system, including a wireless communication interface. The mobile robot may include one or more detectors configured to detect location, navigation, or payload transfers. The mobile robot may include an adjustable width manipulator comprising a plurality of flexible load carriers. The mobile robot may include means that allow it to transit between the horizontal rails and the inclined or vertical rails at intersections of the horizontal rail and the vertical rail by selectively actuating and positioning one or more horizontal actuators and/or one or more vertical actuators to engage or disengage. to a desired horizontal lane or a desired vertical lane.
According to an exemplary embodiment of the present invention, an automated storage and retrieval system includes a multi-level storage structure that includes a plurality of shelving modules separated by aisles, each shelving module having a set of horizontal supports configured to store objects on a plurality of storage levels within each island and a set of horizontal rails associated with each of the storage levels, and at least one set of inclined rails or verticals arranged between and connecting levels of the multi-level storage structure. At least one mobile robot includes one or more horizontal actuators that drive at least one mobile robot in at least one direction along at least one horizontal dimension, and one or more vertical actuators that drive at least one mobile robot in at least one direction along at least one vertical dimension. One or more horizontal actuators engage a set of horizontal rails of the multi-level storage structure, and one or more vertical actuators engage the inclined or vertical rails of the multi-level storage structure. At least one mobile robot propels itself horizontally along the aisles of the multi-level storage structure, and propels itself vertically from level to level of the multi-level storage structure using the inclined rails or Vertical multi-level storage structure.
In accordance with aspects of the present invention, at least one set of inclined or vertical rails may further include moving segments that selectively engage one or more vertical actuators of at least one mobile robot moving from an unengaged position to an engaged position. . At least one set of inclined or vertical rails may be passive and at least one mobile robot may selectively couple to at least one set of inclined or vertical rails by moving one or more vertical actuators from an uncoupled position to a docked position.
In accordance with aspects of the present invention, one or more horizontal actuators may include extendable wheels and one or more vertical actuators may comprise extendable gear wheels. At least απηπ Ln/zznz/E/YiAi one set of inclined or vertical rails may be placed adjacent to the set of horizontal rails. At least one mobile robot can extend the wheels of one or more horizontal actuators and retract the gear wheels of one or more vertical actuators when moving on the set of horizontal rails, and extend the gear wheels of one or more vertical actuators and retract the wheels of one or more horizontal actuators when moving on at least one set of inclined or vertical rails.
In accordance with aspects of the present invention, the system may further include at least one picking station adjacent to at least one island, where at least one of at least one mobile robot can deliver a stored object to a picker at at least one station. of collector. At least one horizontal transit deck may be adjacent to at least two aisles, where the at least one horizontal transit deck allows at least one mobile robot to enter and exit at least two aisles to and from at least one horizontal transit deck, and moves horizontally to any other location also adjacent to at least one transit deck.
In accordance with aspects of the present invention, at least one set of inclined or vertical rails may further include moving segments that selectively engage one or more vertical actuators of at least one mobile robot that is moving from an uncoupled position to a position. coupling position.
According to aspects of the present invention, at least one set of inclined or vertical rails can be passive and at least one mobile robot can be selectively coupled to at least one set of inclined or vertical rails by moving one or more vertical actuators from a position without coupling to a coupling position. One or more horizontal actuators may include extendable wheels and one or more vertical actuators comprise extendable gear wheels. At least one set of inclined or vertical rails may be placed adjacent to the set of horizontal rails. At least one mobile robot can extend the wheels of one or more horizontal actuators and retract the gear wheels of one or more vertical actuators when moving on the set of horizontal rails, and extend the gear wheels of one or more vertical actuators and retract the wheels of one or more horizontal actuators when moving on at least one set of inclined or vertical rails.
In accordance with aspects of the present invention, the system may further include at least one workstation adjacent to at least one horizontal transit deck, where at least one of at least one mobile robot can deliver at least one stored object to an operator. on at least one workstation. At least one stored object may include containers of items and at least one mobile robot delivers a plurality of containers to at least one workstation such that the operator can transfer items between the containers.
According to an exemplary embodiment of the present invention, a transfer mechanism may include at least one flexible load carrier having a support frame, a first horizontal support bar displacement-engaged with the support frame, a second horizontal support bar slidingly coupled with the support frame, a flexible sheet coupled at a first end with the first horizontal support bar and a second end, opposite the first end, with the second horizontal support bar, and a handle coupled απηπ Ln/zznz/E/YiAi with the flexible blade. The transfer mechanism may further include at least one manipulator having first and second linear motion motors that drive the first horizontal support bar or the second horizontal support bar linearly along the support frame, a clamping device adapted to clamp the handle, and a motorized load carrier, attached by a cable to the handle and configured to extend or retract the cable to lower or raise objects into and out of at least one flexible load carrier.
According to aspects of the present invention, the operation of the first and second linear motion motors operate to slide at least one of the first and second horizontal support bars along the support frame to adjust a volume of available space within at least one flexible load carrier to transport one or more objects.
According to an exemplary embodiment of the present invention, an automated period delivery system includes a multi-level Basket Storage Structure that stores one or more Baskets. One or more mobile robots are configured to pick, transport and place one or more Baskets, propel itself horizontally through the levels of the multi-level basket storage structure, and propel itself vertically from level to level within of multi-level basket storage structure using one or more stationary inclined or vertical rails. One or more workstations are configured to accommodate a picker that transports one or more pieces of one or more Baskets on one or more mobile robots to a placement location. An input/output interface where the product is induced into the order delivery system and where fulfilled orders are downloaded from the order delivery systems.
In accordance with aspects of the present invention, one or more mobile robots may be further configured to propel itself vertically from level to level in the order delivery systems while maintaining a horizontal posture. One or more workstations may include an inclined location such that the inclined location supports a mobile robot. The inclined location may support a first mobile robot and where a picker transfers one or more pieces from the first mobile robot to a second robot located above the inclined location.
According to aspects of the present invention, one or more mobile robots include a frame chassis. A Basket transfer mechanism is attached to the frame chassis. Four driven wheel assemblies are coupled to the frame chassis, with each of the four driven wheel assemblies having a drive wheel and a fixed gear wheel.
In accordance with aspects of the present invention, the fixed gear wheel may include a sprocket and one or more stationary inclined or vertical rails may include a chain that engages the sprocket.
In accordance with aspects of the present invention, the system may implement a direct placement process in which parts are transferred in a single operation from an exemplary basket of products to one or more baskets transported by one or more mobile robots directly into a exemplary order basket of one or more baskets transported by one or more mobile robots.
In accordance with aspects of the present invention, the system may implement a direct placement process in which a picked part is placed in a first of one or more Conveyor Baskets by one απηπ Ln/zznz/E/YiAi or more mobile robots that transports the collected part, and then places it in, towards an order basket exemplary of one or more baskets transported by one or more mobile robots.
In accordance with aspects of the present invention, one or more stationary inclined or vertical rails may each include a counterrail channel that engages a bearing on one or more mobile robots to maintain engagement with the vertical rails. The system may further include a door switch at each entry/exit that allows the bearing on one or more mobile robots to enter and exit the counterrail channel when one or more mobile robots enter or exit one or more stationary inclined or vertical rails. and prevent the bearing on one or more mobile robots from leaving the rail when one or more mobile robots are not entering or exiting the counterrail channel. One or more stationary inclined or vertical rails may further include a pair of horizontal mobile robot rails located between vertical rails opposite each elevation at which one or more mobile robots enter or exit the counterrail channel, connecting the pair of robot rails. horizontal movables to movable robot beams of each level and each transit deck. A space may exist between the pair of horizontal moving robot rails immediately adjacent to each of the vertical rails in each of one or more stationary inclined or vertical rails, calibrated, sized and configured to allow the passage of fixed gear wheels of the robot. mobile robot through it when the mobile robot is ascending or descending in the vertical direction.
In accordance with aspects of the present invention, one or more stationary inclined or vertical rails may further include energized charging rails configured to transfer charging energy to one or more mobile robots coupled with one or more stationary inclined or vertical rails. One or more stationary inclined or vertical rails may include switches actuated by any of one or more mobile or motor-driven robots disposed on one or more stationary inclined or vertical rails. One or more stationary inclined or vertical rails may include switches controlled by one or more mobile robots or by a central control system. One or more mobile robots may include an on-board control computer system, including a wireless communication interface. One or more mobile robots may include one or more detectors configured to indicate location, navigation, or payload transfers. One or more mobile robots may include an adjustable width article handler comprising a plurality of flexible load carriers.
According to an exemplary embodiment of the present invention, a mobile robot may include a frame chassis, a transfer mechanism coupled to the frame chassis, a drive shaft, one or more fixed gear wheels mounted on the drive shaft and one or more cylindrical drive wheels mounted on the drive shaft. One or more fixed gear wheels may be configured to engage a stationary rail in an inclined orientation, and one or more cylindrical drive wheels may be configured to travel along a stationary rail in a horizontal orientation. The mobile robot may be configured to operate with a stationary rail using switches to direct the mobile robot between a desired stationary rail in inclined orientation or a desired stationary rail in horizontal orientation.
According to an exemplary embodiment of the present invention, a mobile robot includes a frame chassis, a transfer mechanism coupled to the frame chassis, a drive shaft, one or more fixed gear wheels mounted on the drive shaft and one or more cylindrical drive wheels mounted on the drive shaft. One or more fixed gear wheels may be configured to engage a stationary rail in an inclined orientation, and one or more cylindrical drive wheels may be configured to travel along a stationary rail in a horizontal orientation. The drive shaft may be extendable and retractable to engage or disengage one or more fixed gear wheels and one or more cylindrical drive wheels with a desired stationary rail of the inclined orientation or a desired stationary rail of the horizontal orientation.
According to an exemplary embodiment of the present invention, a mobile robot includes a frame chassis, a transfer mechanism coupled to the frame chassis, a drive shaft, one or more fixed gear wheels mounted on the drive shaft, and a or more cylindrical drive wheels mounted on the drive shaft. One or more fixed gear wheels may be configured to engage a stationary rail in a vertical orientation, and one or more cylindrical drive wheels may be configured to travel along a stationary rail in a horizontal orientation. The drive shaft may be extendable and retractable to engage or disengage one or more fixed gear wheels and one or more cylindrical drive wheels with either a vertically oriented rail or a horizontally oriented rail in such a manner as to allow the Mobile robot selects a desired stationary lane from the vertical orientation or a desired stationary lane from the horizontal orientation without requiring an active lane change.
According to an exemplary embodiment of the present invention, an automated order delivery system includes a multi-level basket storage structure for storing one or more baskets. One or more mobile robots are configured to pick, transport and place one or more baskets, move horizontally through levels of the multi-level basket storage structure, and move vertically between levels from level to level within the multi-level basket storage structure. multi-level baskets using one or more stationary inclined or vertical rails. One or more workstations are configured to accommodate a picker that transports one or more pieces of one or more baskets on one of one or more mobile robots to a placement location. An input/output interface is provided where the product is brought into the order delivery systems and the delivered orders are downloaded from the order delivery systems.
According to one embodiment of the present invention, a mobile robot includes one or more horizontal actuators having wheels that drive the mobile robot in at least one direction along at least one horizontal dimension. One or more vertical actuators have wheels that drive the mobile robot in at least one direction along at least one vertical dimension. One or more horizontal actuators are configured to engage with horizontal rails of a multi-level storage structure, and one or more vertical actuators are configured to engage with inclined or vertical rails of the multi-level storage structure. The wheels of one or more horizontal actuators and/or the wheels of one or more vertical actuators are movable so that the robot can be selectively coupled with horizontal rails and with inclined or vertical rails.
In accordance with aspects of the present invention, wheels of one or more horizontal actuators and απηπ Ln/zznz/E/YiAi the wheels of one or more vertical actuators may be coaxial. Alternatively, the wheels of one or more horizontal actuators and the wheels of one or more vertical actuators may be on separate axles.
According to an exemplary embodiment of the present invention, a mobile robot includes horizontal drive means configured to drive the mobile robot on a horizontal rail. The vertical drive means are configured to drive the mobile robot on an inclined or vertical rail. The robot means allow the transition between the horizontal rail and the inclined or vertical rail at intersections thereof by selectively actuating and positioning the horizontal actuating means and/or the vertical actuating means to engage or disengage from a horizontal rail or a rail. desired inclined or vertical.
According to an exemplary embodiment, a delivery apparatus is provided comprising a multi-level basket storage structure, one or more mobile robots configured to pick, transport and place one or more baskets, one or more workstations configured to accommodate a picker that transports one or more pieces of a basket on one of the mobile robots to a placement location, and an input/output interface where the material is induced towards the order delivery apparatus and where the delivered orders are unloaded from the order delivery apparatus where the mobile robots are further configured to move from level to level in the delivery apparatus of orders via stationary or non-stationary vertical ramps.
According to another exemplary embodiment, an order delivery apparatus is provided comprising a multi-level basket storage structure, one or more mobile robots configured to pick, transport and place one or more baskets; one or more workstations configured to accommodate a picker transporting one or more pieces of a basket on one of the mobile robots to a placement location, and an input/output interface where the material is induced towards the order delivery apparatus and where the delivered orders are unloaded from the order delivery apparatus where the mobile robots are further configured to move from level to level in the delivery apparatus of orders via stationary or stationary vertical ramps and where the mobile robots are further configured to move from level to level in a vertical position.
According to another exemplary embodiment, an order delivery workstation is provided comprising a basket support and an inclined location adjacent to the basket support, where the inclined location supports a mobile robot and where a picker transfers one or more pieces. from the mobile robot to a basket located on the basket support.
According to another exemplary embodiment, an order delivery workstation is provided comprising a basket support and an inclined location adjacent to the basket support; where the inclined location supports a first mobile robot and where a picker transfers one or more pieces from the first mobile robot to a second mobile robot located on the inclined location.
According to another exemplary embodiment, an order fulfillment workstation is provided comprising a product support; an inclined location adjacent to the basket support; a machine vision subsystem; a white illuminator and a collector interface; where the inclined location supports a mobile robot and where a picker transfers one or more parts from the mobile robot to the product support and where the machine vision subsystem follows the movement of the picker and where the illuminator of White illuminates the pieces that will be collected and the places where the pieces will be placed and where the picker interface provides information to the picker.
According to another exemplary embodiment, a mobile robot is provided comprising a frame chassis; a transfer mechanism attached to the frame; two traction actuators coupled to a first end of the frame; two wheels coupled to a second end of the frame and a swivel wheel assembly coupled to the frame; where the two traction actuators and the rotating wheel assembly are coupled to a common surface when the mobile robot is supported on a deck and where the two traction actuators and the two wheels are coupled to rails when the mobile robot is supported by rails .
According to another exemplary embodiment, a mobile robot is provided comprising a frame chassis; a transfer mechanism attached to the frame; four driven wheel assemblies coupled to the frame, each of the four driven wheel assemblies having a drive wheel and a pinion.
According to an exemplary embodiment, an order delivery machine includes a multi-level basket storage structure. A mobile robot is operable within the multi-level basket storage structure to store and retrieve baskets, with the mobile robot having direct access to all basket storage locations. An access door is provided to the client. The mobile robot places the basket to be accessible by a customer at the customer access door.
In accordance with aspects of the present invention, the access door is configurable such that all or only a portion of the basket is accessible to the customer at the customer access door.
Although the primary focus of the application of the present invention is retail supply chains, where the stored objects are baskets of products, which may include pallets, boxes or trays (also called baskets), the invention can also be easily applied to automating the storage and retrieval of other objects.
BRIEF DESCRIPTION OF THE FIGURES
These and other features of the present invention will be more fully understood with reference to the following detailed description in conjunction with the accompanying Figures, in which:
Figure 1A is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 1B is a side view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 2 is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 3 is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 4 is a top view of an exemplary order delivery system according to aspects of the described embodiment;
απηπ Ln/zznz/E/YiAi
Figure 5 is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 6A is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 6B is a side view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 7A is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 7B is a side view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 8A is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 8B is a side view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 9 is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 10A is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 10B is a side view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 11 is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 12 is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 13 is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 14 is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 15 is a side view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 16A is a front view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 16B is a top view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 17 is a partial isometric view of an exemplary order delivery system according to απηπ Ln/zznz/E/YiAi with aspects of the described embodiment;
Figure 18 is a partial isometric view of an exemplary order delivery system according to aspects of the described embodiment;
Figure 19 is a schematic diagram of a control system according to aspects of the described embodiment;
Figure 20A is an elevation view of an exemplary workstation in accordance with aspects of the described embodiment;
Figure 20B is a plan view of an exemplary workstation according to aspects of the described embodiment;
Figure 21A is a plan view of an exemplary workstation according to aspects of the described embodiment;
Figure 21B is an elevation view of an exemplary workstation according to aspects of the described embodiment;
Figure 22A is an elevation view of an exemplary workstation in accordance with aspects of the described embodiment;
Figure 22B is a plan view of an exemplary workstation according to aspects of the described embodiment;
Figure 23A is a schematic isometric view of an exemplary workstation in accordance with aspects of the described embodiment;
Figure 23B is a schematic isometric view of an exemplary workstation according to aspects of the described embodiment;
Figure 23C is a schematic isometric view of an exemplary workstation according to aspects of the described embodiment;
Figure 24A is an isometric view of exemplary workstations according to aspects of the described embodiment;
Figure 24B is an isometric view of exemplary workstations according to aspects of the described embodiment;
Figure 25A is a side view of a vehicle according to aspects of the described embodiment;
Figure 25B is a top view of a vehicle according to aspects of the described embodiment;
Figure 25C is an end view of a vehicle according to aspects of the described embodiment;
Figure 26A is an end view of a module according to aspects of the described embodiment;
Figure 26B is a side view of a module according to aspects of the described embodiment;
Figure 26C is a top view of a module according to aspects of the described embodiment;
απηπ Ln/zznz/E/YiAi Figure 27A is a side view of a vehicle according to aspects of the described embodiment;
Figure 27B is a top view of a vehicle according to aspects of the described embodiment;
Figure 27C is an end view of a vehicle according to aspects of the described embodiment;
Figure 28A is a top and side view of a vehicle according to aspects of the described embodiment;
Figure 28B is a top and side view of a vehicle according to aspects of the described embodiment;
Figure 28C is a top and side view of a vehicle according to aspects of the described embodiment;
Figure 28D is a top and side view of a vehicle according to aspects of the described embodiment;
Figure 28E is a top and side view of a vehicle according to aspects of the described embodiment;
Figure 28F is a top and side view of a vehicle according to aspects of the described embodiment;
Figure 29A is a schematic top view of a drive vehicle according to aspects of the described embodiment;
Figure 29B is a top schematic view of a drive vehicle according to aspects of the described embodiment;
Figure 29C is a schematic top view of a drive vehicle according to aspects of the described embodiment;
Figure 30A is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 30B is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 30C is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 30D is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 31A is a side view of a vehicle according to aspects of the described embodiment;
Figure 31B is an end view of a vehicle according to aspects of the described embodiment;
Figure 31C is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 31D is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 32 is a partial isometric view of a drive vehicle according to aspects of the described embodiment;
Figure 33 is a partial side view of a drive vehicle according to aspects of the described embodiment;
απηπ Ln/zznz/E/YiAi Figure 34A is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 34B is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 35A is a top view of a vehicle according to aspects of the described embodiment;
Figure 35B is a partial side view of a vehicle according to aspects of the described embodiment;
Figure 36A is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 36B is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 37A is a side view of a vehicle with a ramp according to aspects of the described embodiment;
Figure 37B is a side view of a vehicle with a ramp according to aspects of the described embodiment;
Figure 37C is a side view of a vehicle with a ramp according to aspects of the described embodiment;
Figure 37D is a side view of vehicles with a ramp module according to aspects of the described embodiment;
Figure 38A is a side, end and top view of a vehicle with a ramp according to aspects of the described embodiment;
Figure 38B is a side, end and top view of a vehicle with a ramp according to aspects of the described embodiment;
Figure 38C is a side, end and top view of a vehicle with a ramp according to aspects of the described embodiment;
Figure 38D is a side, end and top view of a vehicle with a ramp according to aspects of the described embodiment;
Figure 39A is a side view of vehicles with a ramp according to aspects of the described embodiment;
Figure 39B is an isometric view of vehicles with a ramp according to aspects of the described embodiment;
Figure 39C is an isometric view of a vehicle with a ramp according to aspects of the described embodiment;
Figure 39D is an isometric view of vehicles with a ramp according to aspects of the described embodiment;
Figure 39E is an isometric view of vehicles with a ramp according to aspects of the described embodiment;
Figure 40A is a schematic side view of a transmission according to aspects of the described embodiment;
απηπ Ln/zznz/E/YiAi Figure 40B is a schematic side view of a transmission according to aspects of the described embodiment;
Figure 40C is a schematic side view of a transmission according to aspects of the described embodiment;
Figure 40D is a schematic side view of a transmission according to aspects of the described embodiment;
Figure 41A is a side view of vehicles with a vertical ramp according to aspects of the described embodiment;
Figure 41B is an isometric view of vehicles with a vertical ramp according to aspects of the described embodiment;
απηπ Ln/zznz/E/YiAi Figure 42A is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 42B is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 43A is an isometric view of a vehicle with a vertical ramp according to aspects of the described embodiment;
Figure 43B is an isometric view of a vehicle with a vertical ramp according to aspects of the described embodiment;
Figure 44A is an isometric view of a vehicle with a vertical ramp according to aspects of the described embodiment;
Figure 44B is an isometric view of a vehicle with a vertical ramp according to aspects of the described embodiment;
Figure 45A is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 45B is a side view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 45C is a top view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 45D is an isometric view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 46A is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 46B is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 46C is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 46D is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 47A is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 47B is an isometric view of a vehicle according to aspects of the described embodiment;
Figure 48A is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 48B is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 48C is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 48D is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 48E is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 49A is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 49B is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 49C is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 49D is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 49E is an end view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 50A is an isometric view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 50B is an isometric view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 50C is an isometric view of an orthogonal drive unit according to aspects of the described embodiment;
Figure 50D is an isometric view of an orthogonal drive unit according to aspects of the described embodiment; and Figure 50E is an isometric view of an orthogonal drive unit.
DETAILED DESCRIPTION OF THE INVENTION απηπ Ln/zznz/E/YiAi
Figures 1A through 50E, where like parts are designated by like reference numerals therethrough, illustrate an exemplary embodiment or embodiments of an order delivery system in accordance with the present invention. Although the present invention will be described with reference to the exemplary embodiment or embodiments illustrated in the Figures, it should be understood that many alternative forms may incorporate the present invention. One skilled in the art will additionally appreciate different ways to alter the parameters of the described embodiments, such as the size, shape or types of different materials, so that the spirit and scope of the present invention is still preserved.
The disclosed embodiment can be described as an order fulfillment system for use in supply chains, for example in retail supply chains. The modality is described for delivering retail store orders for boxes of products received from manufacturers or for delivering retail store or individual consumer orders for discrete product units contained in those boxes, referred to herein as pieces (or other commonly used synonyms). They include parts, items, elements), or generally any item ordered by stores or individual consumers in quantities less than a box. Although the modality can be used in other applications, such as the storage or retrieval of parts and processes in work within manufacturing operations, one field of use is the fulfillment of orders in retail supply chains.
Modalities can have the following main component subsystems:
(1) a multi-level shelving structure containing picking stock, generally configured to maximize space utilization by using all available floor-to-ceiling cubic volume;
(2) mobile vehicles or robots, which are autonomous or semi-autonomous vehicles that can receive control commands and perform various transfer and transportation functions depending on the modality, including managing the movement of baskets of products (pick stocks) between storage locations. storage within the shelving structure and workstations;
(3) in delivery modes, for example, workstations at which human or robotic pickers transfer boxes or items either directly to order baskets in some form or to intermediate robots which then transfer them to order baskets, depending of the modality; and (4) a centralized control system, comprising computers, software, and communication components, which manage the operation of the entire system. An operating system may also include one or more input/output interfaces where product is induced into the system to replenish pick stock and delivered orders are downloaded from the system to eventually be delivered to customers, although the details of that interface They will tend to vary across different applications.
Those skilled in the art will appreciate that the transfer mechanisms described herein may vary depending on the application and implementation, based on the particular objects that require storage and retrieval. For various storage and retrieval systems, the transfer mechanism may take some forms, while in order delivery modes, the transfer mechanisms may take other forms, so the present invention is not limited to the transfer mechanisms. specific conditions described herein.
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In the exemplary parts collection mode, the part is the most granular unit of handling, for example, in retail supply chains. The process for delivering parts orders, as usually referred to as parts picking or parts picking, can be the most labor intensive of all delivery processes, especially using traditional picker product process models in which pickers They move to stationary product storage locations to collect ordered parts. In the exemplary embodiment, the word Basket is a system commonly used in the material handling field for a container that contains materials that are stored or handled, and is used hereinafter to refer to both the product and the order containers. . Those skilled in the art will appreciate that in the storage and retrieval implementations of the present invention, containers are used to store and transport objects using mobile robots, and that the basket embodiments are specific forms of containers that are implemented in delivery systems. of orders.
To maximize picking throughput and achieve a very high or even full level of automation, the described modality implements a product process model for the picker in which mobile robotic vehicles transport containers of parts to workstations where stationary pickers ( whether human or robotic) pick or collect ordered parts from containers. The ordered parts can then finally be placed in order containers for eventual delivery to customers, whether stores or individual consumers.
By way of example, two methods of collecting parts are described herein, the essential difference between them being the placement process by which the parts are transferred to the order container. In the first embodiment (El), this transfer process is the typical direct placement process in which each part is transferred in a single movement from the product container directly to the order container. The second modality (E-2) presents an indirect placement process in which this transfer is carried out in two movements: the collected piece is first placed on another mobile robot that serves as an intermediate carrier that transports each piece to, and then places this one in the order container.
Both E-1 (direct placement) and E-2 (indirect placement) may include the following seven elements or subsystems:
(1) Product Baskets (hereinafter referred to as P-Baskets) containing the collection stock of parts used to deliver orders;
(2) Order Baskets (hereinafter referred to as “O Baskets”) containing parts collected to deliver orders;
(3) robotic vehicles (mobile robots) that are self-driving and self-steering, and can transfer and transport payloads, usually (but not always) Baskets, hereinafter referred to as “T-Bots” (or generally “Bots”);
(4) a Basket Storage Structure (hereinafter referred to as “TSS”), which provides structural support for the stored Baskets (both P Baskets and 0 Baskets) and also for the Bots operating therein;
απηπ Ln/zznz/E/YiAi (5) Collection Workstations where human or robotic collectors move pieces from Baskets P and place them on Baskets O or other T-Bot, depending on the modality; and (6) a Central Control System (hereinafter referred to as “CCS”), consisting of software, computers and network equipment, which manages most of the resources within the system (including all the different robots), orchestrates everything the order delivery process and all related processes, and provides status and control interfaces to human operators of the system and external systems;
(7) Input/Output Interfaces (“1/0”) at which T-Bots unload Baskets leaving the system and receive Baskets entering the system.
E-2 (indirect placement) also includes two additional elements or subsystems:
(8) T-Bots equipped with transfer mounts that receive and contain parts collected at Picking Workstations and then transfer them to O-Baskets (as Bots hereinafter referred to as “Part Bots” or simply “E-Bots”) ; and (9) an Order Loading Structure (hereinafter referred to as “OLS”) that provides structural support for O-Baskets being loaded and for O-Bots and E-Bots operating therein;
These elements and their respective interoperation are described in greater detail below. It should be understood that associated with those systems are additional auxiliary equipment and subsystems, such as forklifts for use in the removal of disabled robotic vehicles, safety features for robotic vehicle containment and safe human access, fire suppression systems, etc.
The rails referred to throughout this document refer to supports of various orientations (for example, horizontal, inclined, or vertical) on which mobile robots move. The meaning of the term “lane” is intended to be consistent with the generally accepted definition, which includes an established course to be followed, parallel lanes (for example, to be used by a train or wheeled carriage), single or multiple lanes. that are coupled by wheels or rollers of a cart or similar, channels and/or other forms of indication and guidance of the trajectory of a mobile vehicle or cart, as would be appreciated by those skilled in the art.
Referring now to Figure 1 A, there is shown a schematic top view of an exemplary order delivery system 10. Although the present embodiment will be described with reference to the embodiments shown in the Figures, it should be understood that the present invention can be performed in many forms of alternative modalities. Furthermore, any suitable size, shape or type of materials or elements could be used. The order delivery systems 10 and embodiments described may have features as described and/or may have any combination of features as described in U.S. Patent Application No. 14/213,187 filed May 14, 2014 and titled “ Automated Systems for Transporting Payloads” incorporated as a reference in its entirety. Referring also to Figure 1B, there is shown a side view of an exemplary order delivery system 10. The order delivery systems 10 may have Product Baskets and Order Baskets with robots or mobile vehicles that transfer and transport Baskets. . The Basket Storage Structure 12 is shown as structural support for the stored Baskets and also for the mobile robots operating therein as will be described in more detail. Shown are the mobile robot transit structures 64, 64' through which the mobile robots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and the workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32. Picking Workstations 66,66' are shown arranged at multiple elevations where human or robotic pickers remove pieces from Product Baskets and place them into Order Baskets or a mobile robot, depending on system configuration. The Central Control System 68 is shown consisting of software, computers and equipment, which manages the resources of the system as will be described, for example, with respect to Figure 19. The input/output interface 70 is shown as a conveyor with spurs where the mobile robots receive Baskets that enter the system (Baskets full of product and Empty Order Baskets) and unload Baskets that leave the system (Empty Product Baskets and Baskets of Order filled) on the spurs. The system 60 may utilize vertical rails or towers that allow the I/O 70 of the system to have its own cover.
Referring now to Figure 4, a top view of the exemplary order delivery system 90 is shown. The order delivery system 90 may have Product Baskets and Order Baskets with robots or mobile vehicles receiving and transferring Baskets. The Basket Storage Structure 92 is shown as structural support for stored Baskets and also for the mobile robots operating there as will be described in more detail. Shown are mobile robot transit structures 94 through which the mobile robots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32. Picking Workstations 96 are shown arranged at multiple elevations where human or robotic pickers remove pieces from Product Baskets and place them into Order Baskets or a mobile robot, depending on the system configuration. The Central Control System 98 is shown consisting of software, computers and equipment, which manages the resources of the system as will be described, for example, with respect to Figure 19. The input/output interface 100 is shown as a conveyor with spurs where the mobile robots receive Baskets that enter the system (Baskets full of product and Empty Order Baskets) and unload Baskets that leave the system (Empty Product Baskets and Baskets of Order filled) on the spurs.
Referring now to Figure 5, a top view of exemplary order delivery system 120 is shown. Order delivery system 120 may have Product Baskets and Order Baskets with robots or mobile vehicles receiving and transferring Baskets. The Basket Storage Structure 122 is shown as structural support for stored Baskets and also for the mobile robots operating there as will be described in more detail. Mobile robot transit structures 124 are shown through which the mobile robots move in απηπ Ln/zznz/E/YiAi three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32. Picking Workstations 126 are shown arranged at multiple elevations where human or robotic pickers remove pieces from Product Baskets and place them into Order Baskets or a mobile robot, depending on the system configuration. The Central Control System 128 is shown consisting of software, computers and equipment, which manages the resources of the system as will be described, for example, with respect to Figure 19. The input/output interface 130 is shown as a conveyor with spurs where the mobile robots receive Baskets that enter the system (Baskets full of product and Empty Order Baskets) and unload Baskets that leave the system (Empty Product Baskets and Baskets of Order filled) on the spurs. System 120 may utilize vertical rails or towers that allow the l/O of system 130 to have its own cover.
Referring now to Figures 6A and 6B, they show top and side views respectively of the exemplary order delivery system 150. The order delivery system 150 is shown in a single-ended bidirectional flow system configuration therefore that mobile robots that move bidirectionally within hallways and workstations are configured on a single end. The order delivery system 150 may have Product Baskets and Order Baskets with robots or mobile vehicles receiving and transferring Baskets. The Basket Storage Structure 152 is shown as structural support for stored Baskets and also for the mobile robots operating there as will be described in more detail. Mobile robot transit structures 154 are shown whereby mobile robots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32, Picking Workstations 156 are shown arranged at multiple elevations where human or robotic pickers remove pieces from Product Baskets and place them into Order Baskets or a mobile robot, depending on the system configuration. The Central Control System 158 is shown consisting of software, computers and equipment, which manages the resources of the system as will be described, for example, with respect to Figure 19. An input/output interface 160 is shown where the mobile robots receive Baskets that enter the system (Baskets full of product and empty Order Baskets) and unload Baskets that leave the system (empty Product Baskets and Full Order Baskets). The order delivery system 150 may use vertical rails or towers that allow the I/O of the system 160 to have its own cover. The order delivery system 150 may further have the Order Loading Structure 162 where the Order Loading Structure 162 has similar characteristics to the Basket Storage Structure 152 except where mobile robots can access Baskets from both. sides of the Basket. The Baskets move through the order delivery system 150 in a bidirectional manner 164.
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Referring now to Figures 7A and 7B, they show top and side views respectively of the exemplary order delivery system 180. The order delivery system 180 is shown in a two-ended bidirectional flow system configuration whereby Mobile robots that move bidirectionally within hallways and workstations are configured on both ends. The order delivery system 180 may have Product Baskets and Order Baskets with robots or mobile vehicles receiving and transferring Baskets. The Basket Storage Structure 182 is shown as structural support for stored Baskets and also for the mobile robots operating there as will be described in more detail. Mobile robot transit structures 184, 184' are shown whereby the mobile robots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32. Picking Workstations 186, 186' are shown arranged at multiple elevations where human or robotic pickers remove pieces from Product Baskets and place them into Order Baskets or a mobile robot, depending on the system configuration. The Central Control System 188 is shown consisting of software, computers and equipment, which manages the resources of the system as will be described, for example, with respect to Figure 19. The input/output interface 190 is displayed where the mobile robots receive Baskets that enter the system (Baskets full of product and empty Order Baskets) and unload Baskets that leave the system (empty Product Baskets and Order Baskets full). The order delivery system 180 may use vertical rails or towers that allow the I/O of the system 190 to have its own cover. The order delivery system 180 may further have the Order Loading Structure 192,192' where the Order Loading Structure 192,192' has similar characteristics to those of the Basket Storage Structure 182 except where mobile robots can access the Baskets. from both sides of the Basket. The Baskets move through the order delivery system 180 in a bidirectional manner 194.
Referring now to Figures 8A and 8B, they show top and side views respectively of the exemplary order delivery system 210. The order delivery system 210 is shown in a two-ended unidirectional flow system configuration whereby Mobile robots that move unidirectionally within hallways and workstations are configured on the side of the system 210 accessible from both ends. The order delivery system 210 may have Product Baskets and Order Baskets with robots or mobile vehicles receiving and transferring Baskets. The Basket Storage Structure 212 is shown as structural support for stored Baskets and also for the mobile robots operating there as will be described in more detail. Mobile robot transit structures 214,214' are shown through which mobile robots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32. απηπ Workstations Ln/zznz/E/YiAi
Picking 216 are shown arranged at multiple elevations where human or robotic pickers remove pieces from Product Baskets and place them into Order Baskets or a mobile robot, depending on the system configuration. The Central Control System 218 is shown consisting of software, computers and equipment, which manages the resources of the system as will be described, for example, with respect to Figure 19. The input/output interface 220 is displayed where the mobile robots receive the Baskets that enter the system (Baskets full of product and empty Order Baskets) and unload Baskets that leave the system (empty Product Baskets and Full Order Baskets). System 210 may utilize vertical rails or towers that allow the l/O of system 220 to have its own cover. The Baskets move through the system 210 in a unidirectional manner 224.
Referring now to Figure 9, a top view of exemplary order delivery system 240 is shown. Order delivery system 240 is shown in a direct placement, two-ended unidirectional flow system configuration whereby the Mobile robots move unidirectionally within aisles and workstations are configured on the side of system 240 as drop-in workstations accessible from both ends. The order delivery system 240 may have Product Baskets and Order Baskets with robots or mobile vehicles receiving and transferring Baskets. The Basket Storage Structure 242 is shown as structural support for stored Baskets and also for the mobile robots operating there as will be described in more detail. Mobile robot transit structures 244, 244' are shown in which mobile robots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32. Picking Workstations 246 are shown arranged at multiple elevations where human or robotic pickers remove pieces from Product Baskets and place them into Order Baskets or a mobile robot, depending on the system configuration. The central control system 248 is shown consisting of software, computers and network equipment, which manages the system resources as will be described, for example, with respect to Figure 19. The input/output interface 250 is displayed where the mobile robots receive the Baskets that enter the system (Baskets full of product and empty Order Baskets) and unload Baskets that leave the system (empty Product Baskets and Full Order Baskets). The Baskets move through the system 240 in a unidirectional manner 252.
Referring now to Figures 10A and 10B, they show top and side views respectively of the exemplary order delivery system 270. The order fulfillment system 270 is shown in a direct placement, single-ended bidirectional flow system configuration whereby mobile robots that move bidirectionally within aisles and workstations are configured on the end of the system 270 as drop-in workstations accessible from one end. The order delivery system 270 may have Product Baskets and Order Baskets with robots or mobile vehicles receiving and transferring Baskets. The Basket Storage Structure 272 is shown as structural support for stored Baskets and also for the mobile robots operating there as will be described in more detail. απηπ Ln/zznz/E/YiAi mobile robot transit structures 274 are shown in which mobile robots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32. Picking Workstations 276 are shown arranged at multiple elevations where human or robotic pickers remove pieces from Product Baskets and place them into Order Baskets or a mobile robot, depending on the system configuration. The Central Control System 278 is shown consisting of software, computers and equipment, which manages the resources of the system as will be described, for example, with respect to Figure 19. The input/output interface 280 is displayed where the mobile robots receive the Baskets that enter the system (Baskets full of product and empty Order Baskets) and unload Baskets that leave the system (empty Product Baskets and Full Order Baskets). The Baskets move through the system 270 in a bidirectional manner 282.
Referring now to Figure 11, a top view of exemplary order delivery system 300 is shown. The order fulfillment system 300 is shown in a direct placement, two-ended bidirectional flow system configuration whereby mobile robots that move bidirectionally within aisles and workstations are configured on both ends of the system 300 as stations. drop-in work surfaces accessible from both ends. The order delivery system 300 may have Product Baskets and Order Baskets with robots or mobile vehicles receiving and transferring Baskets. The Basket Storage Structure 302 is shown as structural support for stored Baskets and also for the mobile robots operating there as will be described in greater detail. Mobile robot transit structures 304, 304' are shown in which mobile robots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32. Picking Workstations 306,306' are shown arranged at multiple elevations where human or robotic pickers remove pieces from Product Baskets and place them into Order Baskets or a mobile robot, depending on the system configuration. The Central Control System 308 is shown consisting of software, computers and equipment, which manages the resources of the system as will be described, for example, with respect to Figure 19. The input/output interface 310 is displayed where the mobile robots receive the Baskets that enter the system (Baskets full of product and empty Order Baskets) and unload Baskets that leave the system (empty Product Baskets and Full Order Baskets). The Baskets move through the system 300 in a bidirectional manner 312.
Referring now to Figure 12, a top view of exemplary order delivery system 330 is shown. The order delivery system 330 is shown in an indirect placement, single-ended bidirectional flow system configuration whereby mobile robots moving bidirectionally within απηπ Ln/zznz/E/YiAi of aisles and workstations are configured on one end of system 330 as indirect placement workstations accessible from the center. The order delivery system 330 may have Product Baskets and Order Baskets with robots or mobile vehicles receiving and transferring Baskets. The Basket Storage Structure 332 is shown as structural support for stored Baskets and also for the mobile robots operating there as will be described in more detail. Shown are mobile robot transit structures 334, 334' through which mobile robots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32. Picking Workstations 336 are shown arranged at multiple elevations where human or robotic pickers remove pieces from Product Baskets and place them into Order Baskets or a mobile robot, depending on the system configuration. The Central Control System 338 is shown consisting of software, computers and equipment, which manages the resources of the system as will be described, for example, with respect to Figure 19. The input/output interface 340 is displayed where the mobile robots receive the Baskets that enter the system (Baskets full of product and empty Order Baskets) and unload Baskets that leave the system (empty Product Baskets and Full Order Baskets). The order delivery systems 330 may further have the Order Loading Structure 342 where the Order Loading Structure 342 has similar characteristics to those of the Basket Storage Structure 332 except where mobile robots can access Baskets from both sides of the Container. The Baskets move through the system 330 in a bidirectional manner 344.
Referring now to Figure 13, a top view of the exemplary order delivery system 360 is shown. The 360 order fulfillment system is shown in a single-ended, drop-in, one-way flow system configuration whereby mobile robots moving unidirectionally within aisles and workstations are configured on one side of the system. 360 as drop-in workstations accessible from the middle. The 360 order delivery system may have Product Baskets and Order Baskets with robots or mobile vehicles receiving and transferring Baskets. The Basket Storage Structure 362 is shown as structural support for stored Baskets and also for the mobile robots operating there as will be described in more detail. Mobile robot transit structures 364, 364' are shown whereby mobile robots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32. Picking Workstations 366 are shown arranged at multiple elevations where human or robotic pickers remove pieces from Product Baskets and place them into Order Baskets or a mobile robot, depending on the system configuration. The Central Control System 368 is shown consisting of software, computers and work equipment, which manages the resources of the system as will be απηπ Ln/zznz/E/YiAi described, for example, with respect to Figure 19. The input/output interface 370, 370' is shown where the mobile robots receive Baskets that enter the system (full Product Baskets and empty Order Baskets) and unload Baskets that leave the system (empty Product Baskets and full Order Baskets ). The order delivery systems 360 may further have the Order Loading Structure 372 where the Order Loading Structure 372 has similar characteristics to the Basket Storage Structure 362 except where mobile robots can access Baskets from both sides. of the Container. The Baskets move through the system 360 in a unidirectional manner 374.
Referring now to Figure 14, a top view of exemplary order delivery system 390 is shown. Order delivery system 390 is shown in an exemplary case picking configuration. The order delivery system 390 may have boxes with robots or mobile vehicles that transfer and transport boxes to and from the warehouse and then from the warehouse to the pallet workstations 396. The box storage structure 392 is shown as a structural support for stored boxes and also for the mobile robots operating there as will be described in more detail. Mobile robot transit structures 394,394' are shown whereby the mobile robots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on rails or vertical ramps that interconnect storage lanes and workstations at multiple elevations, and without the requirement of a vertical elevator or vertical conveyor provided by the multi-level Basket Storage Structure 32. Pallet workstations 396 are shown arranged at multiple elevations where human or robotic pickers pick boxes (after being placed by mobile robots) from shelves and place them on pallets which can then be palletized and exited via conveyor or another way. The Central Control System 398 is shown consisting of software, computers and work equipment, which manages the system resources as will be described, for example, with respect to Figure 19. The input interface 400 is shown where the mobile robots They receive boxes that enter the system via the conveyor where the mobile robots can transport one or more boxes to the box storage structure 392.
Referring now to Figures 15 and 16A-16B, they show side, front and top views respectively of the exemplary order delivery systems configured in a sales configuration. Referring also to Figures 17 and 18, they show partial isometric views respectively of the exemplary order delivery systems. Here, the order delivery systems may be described as an order vending machine 420 or “OVM” or otherwise. The order vending machine 420 shows an alternative smaller scale version of, for example, the robotic vehicle and shelving system, for example, which may be used in stores selling delivered products or any other suitable application. For example, vehicle technology used in e-commerce applied to the “last mile” delivery problem. For example, “Fair Play” e-commerce companies have little choice but deliver the vast majority of orders to customers' homes, which can be expensive. Retailers operating self-service and online stores may offer customers the choice of picking up orders at the store location, commonly called “click απηπ Ln/zznz/E/YiAi and pick up,” but in practice This model places an additional and unpredictable workload on store staff which can result in long customer wait times, etc. Here, the order vending machine 420 provides an automated solution that requires very little floor space (or land) but can safely hold a large number of orders, and that also provides convenient on-demand access and short transaction times to the clients. Here, the order vending machine 420 may be a “micro-warehouse” based robotic vehicle that may be referred to as an Order Vending Machine (OVM) that operates in conjunction with an e-commerce delivery center, for example one equipped with a robotic vehicle based on the system. In one aspect, Order Baskets (O Baskets) containing customer orders may be delivered to and stored within the OVM, and then presented on demand to customers, with robotic vehicles performing all basket storage and retrieval functions. required. Here, Figures 15-18 show one embodiment of an order vending machine system 420, which comprises a single aisle 422 with two opposing multi-level storage modules 424, 426, a Bot Tower 428, 430 in one or both alternately ends of the hallway, an I/O interface 432, 434 on each Bot Tower, at least one robotic vehicle 436 (or T-Bot/Basket Bot), and a controller 438 with wired connections to the l/O 432, 434 and wireless communication with the T-Bots. T-Bots use the vertical towers to access any storage level and horizontal Bot lane within the hallway to access any basket position on a given level. Baskets 440 may also be stored adjacent to each Bot Tower, except for the three consecutive basket positions on the side of the tower that are used by the input/output interface, where baskets are received and removed during deliveries and also where the customer receives their orders contained in the baskets. An OVM can only operate with a single T-Bot. Alternatively, more than one may be provided, for example a second (or more) robotic vehicle may be effective, for example, in increasing throughput during delivery processing, thereby minimizing residence time for both of the vehicles. lane and actuator, and customer service levels are improved by the reduction in order picking transaction times and by the ability to serve customers concurrently. Similarly, an OVM can operate with a single Bot Tower at one end of the hallway, but configuring a tower at each end of the hallway can be effective as it provides two I/O interfaces, allowing concurrent service to two clients ( or a client concurrently with delivery processing).
The I/O interface consists of a shelf 442 containing a single basket, a mobile access panel 444, and a human/machine interface (HMI), such as a touch screen display device 446. Both of the access panel and the HMI are connected to and controlled by the controller. The access panel is selectively one closed position, which blocks all access, and two or more open positions. A fully open position allows the basket on the shelf to be completely removed or an external basket to be placed on the shelf; This position is used during delivery transactions. The other open positions provide a customer with access to reach the contents of a basket corresponding to that individual customer order since baskets will typically contain multiple orders. Figure 17 shows exit doors with sliding shutters while Figure 18 απηπ Ln/zznz/E/YiAi shows alternative exit doors with hinged covers, for example, covers that have one or more solenoids to close the lock (shown in the front part). Alternatively, the covers can also be held open by a passive magnet when a hopper is receiving products. Additionally, the covers may have a stop so that they do not slam shut. In one respect, it might also be useful to configure the two 1/0 ports differently. Maybe the left side is 1/4 divided and the right side is completely accessible. Depending on the basket, they can be directed to the divided or full access side. Alternatively, any suitable combination can be used.
System operation generally involves two types of transactions: basket removal/insertion transactions and order picking transactions. Remove/insert transactions occur during the processing of a delivery, when an operator arrives with new baskets that will be placed in the warehouse at the OVM. The operator inserts the baskets into an L/O interface and interacts with the HMI to cause the controller to open the access panel to the fully open position to initiate remove/insert transactions via the T-Bots in the system. . In each remove/insert transaction, a T-Bot receives an output basket (typically empty) from the warehouse, transports it to the I/O interface, and places it on the shelf, after which the operator removes it. The operator then places an input basket on the shelf, which the T-Bot transports to the warehouse. Remove/insert transactions continue until there are no more output or input baskets that need to be removed or inserted, respectively. The operator then walks away with the output baskets, which are returned to the delivery center and later reused to hold future orders.
When a customer arrives at the OVM to pick up an order, they interact with the HMI on an I/O interface to validate their identity, after which the controller initiates one or more order picking transactions carried out by the T-Bots. Each of these transactions begins with the T-Bot retrieving a basket containing items ordered by the customer from the warehouse, transporting the basket to the L/O interface, and placing it on the shelf. Upon arrival of a basket O on the shelf, the controller operates the access panel to create an opening immediately around the items ordered by the customer, after which the customer removes the items from the basket. Once all items have been removed, the controller closes the access panel and instructs the T-Bot to return the basket to the warehouse.
Although this description focuses on the transfer of e-commerce orders to customers, it can be easily seen that the same system can be used generically to implement a product vending machine on a very large scale, which can contain the same assortment of SKUs. to the one found today in small convenience stores. In this application, the baskets would be product baskets rather than order baskets, and the customer's interaction with the HMI would involve ordering items contained in the P-Baskets, rather than picking up ordered products delivered from a remote delivery center, i.e. That is, the customer's order is delivered to the OVM point. For this, the same OVM can perform both functions at the same time.
To illustrate the space efficiency of the OVM, the specific modality illustrated can be approximately 2 meters wide and 6 meters in both length and height, so that it has a footprint of 12 απηπ Ln/zznz/E/YiAi square meter. Here, the modality can have a maximum storage capacity of 340 baskets. Since multiple orders or SKUs may be contained in each basket O or basket P respectively, and may still allow for the empty basket positions necessary for efficient operation, this OVM can store between 500 and 2,000 customer orders and/or SKUs.
Referring now to Figure 19, a schematic diagram of the control system 450 is shown. The control system 450 may have the warehouse management system 452, the adaptive interface layer 454, the inventory and performance data repository. 456, robot/vehicle master controller 458, on-board robot vehicle control 460 and workstation controller 462.
Additional modules may be provided to control additional equipment, for example, additional material handling, robotic, safety or other modules. The control system 450 may further be configured with more or fewer modules or submodules. The robot/vehicle master control 458 may have modules such as a program optimizer, dispatch rules, order management, replenishment manager, Ul, robot manager, traffic manager, warehouse manager, security systems manager, and manager of workstation. The 462 workstation controllers may have modules such as a basket or order basket manager, Ul, security systems manager, vision system, and lighting controller. In alternative aspects, more or fewer modules may be provided. An exemplary embodiment may comprise a non-transitory program storage device (such as memory 456 for example) readable by a machine, which tangibly incorporates a program of instructions executable by the machine to perform operations, the operations comprising controlling, at least partially, an order delivery system.
The order fulfillment systems as described share, at least in part, common components and subsystems that may be configured in any suitable combination or subcombination alone or in combination with other components and subsystems. Order fulfillment systems may include multi-level racking structures for stock storage (or “pick stock”), typically configured to maximize space utilization by using all available floor-to-ceiling cubic volume for storage modules. shelves containing products in the warehouse separated by aisles so that robots have access to product storage locations, and subdivided horizontally into a plurality of “floors,” each floor comprising a plurality of storage levels. Order delivery systems may also include mobile robots (“Bots”), autonomous or semi-autonomous vehicles that iterate freely, that is, they have full access to all portions of the system, and perform various transfer and transportation functions depending on the modality. , for example the movement of product containers between storage locations within the shelving structure and workstations. Bots can be considered autonomous or semi-autonomous since in the illustrative embodiments they can receive control orders and have sufficient computing hardware to store the orders and then carry out various processes autonomously to execute the order (where the order can be, for example, collect each X and deliver it to destination Y, which would then require the Bot to autonomously determine the steps necessary to execute the order). As described herein, the order delivery systems include a Central Control System, which has control over the Bots as well. Therefore, mobile robots are not required to be completely autonomous to identify what they need to do and how they need to do it. There is some degree of governance of the Bots provided by the Central Control System. Whether specific governance tasks are carried out by the Bots or by the Central Control System will vary depending on the particular implementation of the order delivery systems, as would be appreciated by those skilled in the art. Order delivery systems may also include Bot transit structures in which Bots move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure, workstations and/or 1/0 interfaces. on a given plant; and vertically over vertical or diagonal ramps that interconnect any storage level within a floor (aisle ramps) or floors (transit ramps), and without the requirement of a vertical elevator or vertical conveyor provided by the basket storage structure. multiple levels. Order delivery systems may further include workstations at which humans or robots transfer picked parts or boxes either directly into order containers or to intermediate robots which then transfer the order containers, depending on the modality. Order delivery systems may further include input and output interfaces whereby product is induced into the system to replenish picking stock (inbound) and picked or picked orders are downloaded from the system to eventually be delivered to customers. (exit). Order delivery systems may also include a Centralized Control System, comprising computers, software and communication components, which manages the operation of the entire system. Accordingly, all suitable combinations may be provided in whole or in part.
In the context of exemplary order fulfillment systems and appropriate combinations of those subcomponents and systems, various operating scenarios and subsystems will now be described in greater detail.
The order delivery technology described may be primarily for use in retail supply chains to deliver unit (“piece”) orders of individual items, for example orders placed by smaller convenience stores to replenish inventories (e.g. drugs, convenience or others); or orders placed by end users (direct to consumer). Alternatively or in combination, the order fulfillment technology described can be applied to case picking, for example, order fulfillment of product cases by self-service retail warehouses to replenish their inventory, which uses the product process. to plank
Those orders can be delivered in a “product-to-picker” process that uses free-ranging mobile robots operating within a structured, closed, three-dimensional environment to perform all movement of product containers, including: 1) receive incoming product containers and place them in the warehouse on a racking structure to replenish pick stock, retrieving containers from the warehouse as required to deliver orders, transporting those containers to Workstations απηπ Ln/zznz/E /YiAi Picking where human or robotic pickers remove items, then returning the containers to the warehouse, and finally unloading empty containers from the system to be replenished for another cycle of use, and 2) receiving incoming empty order containers, placing them in a position to receive ordered parts and keeping the customer pending delivery, placing full order containers in the warehouse when necessary, and unloading filled order containers from the system for delivery to customers. Mobile robots can have fully random and autonomous access directly to all locations within the system's operating environment, including all storage locations, all workstations, and all receiving and shipping locations, by virtue of having the autonomous capacity to move in all three dimensions within that environment, that is, two horizontal dimensions as well as the vertical dimension. Two alternatives are described, the difference between them being related to the process used in the transfer of pieces from product containers to order containers: 1) in the direct placement modality, the collected pieces are transferred directly from a product container to an order container, which is the model process commonly practiced in the field; and 2) in the indirect placement modality, the collected pieces are not transferred directly to product containers but to intermediate robots that transport them and then transfer them to the assigned order containers.
DIRECT PLACEMENT SYSTEM
In a drop-in system, parts are transferred directly from product baskets to order baskets. This process can minimize the number of part transfers and thus minimize the capital investment required for a given application. Compared to the indirect placement modality described below, this has several differences. The first difference is the specificity of the workstation, that is, once a basket OR designated to receive order lines from a given customer is assigned an order to a given workstation, the collection of parts to deliver those lines of The order can only be made at that specific workstation, which can lead to delays due to robots interfering with each other or otherwise trying to reach their assigned destinations. The second difference is related to the first and the use of multi-order workstations where a number of O-Baskets are processed concurrently, which extends the order delivery latency for a given O-basket, i.e. the time spent in the Picking Workstation, since it shares parts picking resources with all other concurrent O-Baskets.
The direct placement system can have eight elements or subsystems. Product baskets (“P Baskets”) are containers for the collection stock of parts used to deliver orders. Order baskets (“O Baskets”) are containers of parts that have been picked to deliver specific orders. Mobile robots are robots that transfer and transport baskets (“T-Bots”), Bots tasks are typically round-trip transactions consisting of two segments, the first segment being the removal of a basket from the warehouse at the TSS. and transportation to a destination, with the second segment being the return of the basket from that same destination to the warehouse in the TSS, so the Bots are almost always moving with a basket payload on board. A T-Bot that handles a P basket is referred to as a P-Bot, while a T-Bot that handles an O basket is referred to as an O-Bot; a given T-Bot can switch roles on a transaction-by-transaction basis, for example by serving as an απηπ Ln/zznz/E/YiAi
P-Bot in a transaction and then immediately perform as an O-Bot in a very close transaction. The Basket Storage Structure (“TSS”) provides structural support for stored T-baskets (both P-Baskets and 0-Baskets) and also for the Bots operating there, generally configured to maximize space utilization using all the available floor-to-ceiling cubic volume for shelving modules containing baskets in the warehouse separated by aisles that provide robots with access to basket storage locations. Bot Transit Structures (“BTS”) allow Bots to move in three dimensions: horizontally on flat transit decks that interconnect the shelving structure and workstations; and vertically on vertical rails that interconnect storage lanes and workstations at multiple elevations. Alternatively, the Bot Transit Structure (BTS) may comprise hallway ramp modules, transit ramps and transit decks. Picking Workstations are arranged at multiple elevations where human or robotic pickers remove pieces from P-Baskets and place them into O-Baskets or a robot, depending on the modality. A Central Control System (CCS) consists of software, computers and network equipment, which manages the system resources (including all the different robots), orchestrates the entire order delivery process and all related processes, and provides state and control interfaces to human system operators and external systems. One or more Input/Output Interfaces (“1/0”) at which T-Bots receive baskets entering the system (full P-Baskets and empty O-Baskets) and unload baskets leaving the system (empty P-Baskets and Baskets O full).
Operation processes, controlled directly or indirectly by the CCS
P-Baskets flow to the picking stations so T-Bots retrieve P-Baskets containing ordered products from the warehouse at the TSS, transport P-Baskets to specific Picking Workstations based on the location of the order baskets specific targets, and then return the P Baskets to the warehouse at the TSS. Typically, P Baskets are returned to the warehouse at the TSS even if the last remaining of each have been picked or collected and the basket is empty.
O-Baskets flow to and from Picking Workstations so O-Bots deliver empty O-Baskets to workstations to be filled with parts ordered by customers and also remove full O-Baskets from workstations; The removal of a full O-Basket and the delivery of an empty O-Basket typically occurs over the same round-trip transaction. Typically the O-Bot first removes an empty O-basket from the store at the TSS, transports those baskets to the 1/0 interface for unloading, immediately collects a full O-basket and departs from the workstation. The filled O-Baskets are then typically transported to storage locations at the TSS depending on delivery to customers, although they may alternatively be taken directly to the 1/0 interface for immediate delivery.
Picking and placing at workstations occurs where P-Bots present P-Baskets to human or robotic pickers, who remove one or more pieces from each P-basket and place them in designated O-Baskets (described in more detail below).
The delivery of the order and induction of the O basket occurs by virtue of the T-Bots removing from the απηπ Ln/zznz/E/YiAi warehouse at the TSS (or alternatively directly from the Picking Workstations) filled O Baskets that are to be downloaded from the system for delivery to customers and transported to the 1/0 interface. Here, empty O-Baskets are inducted into the system via the 1/0 interface and are typically transported by the T-Bot to a storage location in the TSS, where they will remain pending transport to a Picking Workstation. , although they can promptly (and more efficiently) be transported directly to a workstation if needed immediately.
Picking and recycling stock replenishment of P-Baskets includes TBots receiving incoming full P-Baskets at the 1/0 interface and transporting them to the warehouse at the TSS (or occasionally directly to the Picking Workstation). ). The T-Bots also remove empty P-Baskets from the TSS warehouse and deliver them to the 1/0 interface to be downloaded from the system for replenishment.
Components of the Direct Placement System
P Baskets and O Baskets
The P-Baskets and O-Baskets are preferably dimensionally identical so that any T-Bot can manipulate them either with a fixed width basket transfer mechanism, and which subsequently plays the roles of P-Bots and O-Bots. For example, both baskets can have a length of 600 mm, width of 400 mm and height of 300 mm, a widely used standard size, with the height depending on the application based on the most efficient volume for a specific product assortment and other typical sizes. P-Baskets may be subdivided into multiple compartments, each of which may contain a different SKU, in which case the baskets referred to as a “multi-SKU” P-basket (with “SKU” being an acronym for a “unit held in existence”, which means a unique product. Similarly, O-Baskets may be subdivided into multiple compartments or may contain multiple separate shipping containers, in which case the basket is referred to as a “multi-order” O-basket.
Basket Storage Structure (“TSS”)
The Basket Storage Structure is a storage system for containing baskets, comprising a plurality of steel shelving modules separated by aisles. Shelving modules use frame assemblies as vertical columns, to which are attached the horizontal beams that support the baskets in the warehouse. The shape of the beam that is oriented toward the aisle includes a horizontal extension from the bottom of the beam that provides the running surface for the Bot wheels, therefore called “Bot Beams.” The shelf design depends on the method the Bots use to transfer baskets: i) if the Bots lift the baskets, two beams are the only support required, and the baskets will be stored only one depth (two baskets between adjacent aisles) ; i) if the Bots slide the baskets across the shelf, beams are necessary between the basket holder, for example wire mesh; Compared to a lift transfer, Bots are less expensive but the storage rack is more expensive; However, slide transfer makes it possible to store the basket at double (or greater) depth (four or more baskets between adjacent aisles), which increases storage density and reduces construction costs compared to warehouse at a single depth απηπ Ln/zznz/E/YiAi;
The Basket Storage Structure can be subdivided horizontally to form “Floors” — groups of interconnected storage levels. The number of plants is a performance factor because the larger the number of Plants the more Bots can operate within the system without excessive congestion. Each floor subdivision within a hallway creates a single “Storage Zone,” provided with a floor so maintenance technicians can enter that zone to resolve any issues; The single zone must be closed to all Bot activity during maintenance visits, but the rest of the system can continue operating.
Bot Transit Structures (“BTS”)
The Bot Transit Structure has transit decks which are flat structures that serve as paths along which Bots can move in two horizontal dimensions between TSS corridors and Collection Workstations. Decks can typically be constructed of plywood panels over a steel support frame. Transit Decks are located at multiple elevations vertically, specifically at each workstation level.
BTS - Alternativa Vertical
Vertical Lanes (or simply “Vertical”) are structural subassemblies by which Bots can move vertically up and down to move to any level in the warehouse in a hallway or to any workstation level. There are advantageously two verticals at one end or both ends of each aisle, depending on whether there are transit decks over one or both ends of the aisles. One vertical is for scrolling up, the other is for scrolling down. The uprights at one or both ends of the aisles are located between the aisles and transit decks, with the upright attached to the transit deck and the downright attached to the aisle. Figures 43A and 43B show isometric views of vehicles with a vertical ramp 1170. Accordingly, the robot 1172 can climb the verticals 1174. Here, buttress rails have vertical landings where the buttress can enter. Shown here is a passive switch 1176 for an upward ramp where the robot 1172 is entering horizontally from the left. In Figure 43B, the robot 1172 climbs the vertical 1174 where the switch 1176 is pushed outward for the Bot to climb. In the case of the down ramp, the switch is normally open and can be pushed to close or to allow the Bot to exit onto the horizontal rail. Each vertical includes four vertical chain rails that are constructed of roller chain welded to a U-shaped channel; Four 1178 pinion gear wheels on the robots engage those chain rails. Associated with each chain rail is a buttress rail 1180 which engages a bearing 1182 at the end of the gear wheel shaft and ensures that the sprocket on the Bot remains properly engaged with the chain rail. At each entry/exit level is a hinged door switch 1176 which allows the bearings to enter and exit the counterrail channel if a Bot is entering or exiting the vertical, but also prevents the bearing from exiting the channel if a Bot is entering or exiting the vertical. Bot is passing through that level without exiting. Each vertical also includes a pair of horizontal Bot rails 1184 located between chain rails opposite each elevation at which Bots can enter or exit the ramp, connecting the rails to the Bot beams of each level απηπ Ln/zznz/E /YiAi from warehouse and each transit deck. The lane spacing (distance between lanes) is the same as the aisle width at the connection point of the Corridor Bot beams but is widened slightly more than the Bot width near the chain rails to allow Bots to that ascend or descend pass between the lanes. There is a gap in the Bot rail immediately adjacent to each of four chain rails, which allows the sprocket axles of a vertically ascending or descending Bot to pass through the rail. The upward verticals can be equipped with charging rails so that Bots can recharge their supercapacitors while ascending. Referring also to Figures 41A and 41B, side and isometric views are shown respectively of verticals with a vertical ramp 1110. Here, the vehicle 1140 scales the verticals 1114 in a vertical scaling configuration of the robot. The difference in this embodiment is that the gears 1142 are perpendicular to the direction of travel. Here, gear 1142 extends outward through a gap in the “outer horizontal rail” for scaling. An electronic level may be provided on the robotic vehicle to detect roll separation and variation so that servomotors can be adjusted to maintain level variations of the robotic vehicle and eliminate formation. Referring also to Figures 42A and 42B, isometric views of the vehicle 1140 are shown, showing the gears 1142 extended in Figure 42A and retracted in Figure 42B. Those skilled in the art will appreciate that the pinion gears with chains described in this embodiment and other embodiments do not limit the invention, and that other equivalent structures, such as rack and pinion, or the like, may be used.
Referring now to Figures 47A and 47B, they show isometric views of the robotic vehicle 1260 engaging the uprights 1262. Figure 47A shows the front of the “single axis” Bot while Figure 47B shows the rear of the Bot. “single axis”. Referring also to Figures 48A through 48E, end views of the orthogonal drive unit joint 1290 are shown. Referring also to Figures 49A through 49E, rear views of the orthogonal drive unit joint 1320 are shown. Referring also to Figures 50A through 50E, isometric views of the drive unit joint are shown. orthogonal 1320. Figure 50A shows the wheel inside, the pinion inside, in the position when driven through a rack system. Figure 50B shows the wheel out, pinion in, position when activated horizontally across a vertical zone. Figure 50C shows the wheel out, sprocket out, buttress not fully extended, from the position when both Bots drive up toward the vertical chain. Figure 50D shows wheel off, pinion off, buttress off with the robotic vehicle ready to climb down or land on horizontal rails. Figure 50E shows the wheel in, sprocket out, buttress out, from the position when the Bot is climbing across horizontal rails.
Referring now to Figures 44A and 44B, they show isometric front views of vertical climbing vehicles of alternative modalities with a vertical ramp 1200. Referring also to Figures 45A to 45D, they show views from one end, side, upper and isometric, respectively of the orthogonal drive unit 1230. Referring also to Figures 46A through 46D, end views of the orthogonal drive unit 1230 are shown. The joint drive of the orthogonal drive unit is shown with the center joint driven vertically. Figure 46A shows the wheel inside, the pinion inside.
απηπ Ln/zznz/E/YiAi
Figure 46B shows the wheel outside, the pinion inside. Here, the end of the center link is in the same position and the link allows the wheel to be driven out passively by the spring. Figure 46C shows the wheel outside, the pinion inside. Figure 46D shows the wheel inside, the pinion inside. Here, the drive wheel is removed from the Bot wheel and the distance from the center of the motor to the center of the driven sprocket is 13mm larger making the belt engage the drive sprocket at the same time. Here, the linkage is horizontal creating a rigid engagement of the sprocket on the vertical chain, like a pin over center. In this mode, the upper sprocket is passive and can be used for the stability of the Bot on the roller axis.
BTS – Passive Ramp Alternative
Aisle ramps (passive lane mode) are structural subassemblies (modules) that interconnect the warehouse levels within a given storage area (a floor section of an aisle) and the transit deck of that floor. Figures 37A through 37C show side and top views of the exemplary vehicle with ramp 990 and Figure 37D shows a side view of exemplary vehicles with ramp module 990'. Each hallway ramp module provides the path for Bots to move between the transit deck and any of the interconnected warehouse levels. The movement can be bidirectional or unidirectional depending on the topology of the system, that is, single-ended or double-ended, respectively. Each ramp module includes four diagonal ramp rails 992, one for each of the four wheels on a Bot 994, which are constructed of passive roller chain welded to a U-shaped channel. The roller chain on each rail It is engaged by one of four gear wheels on the robot. Four rails allow the robot to remain horizontal when ascending or descending the diagonal ramp. Each ramp module also includes a pair of horizontal Bot lanes 996 located between ramp lanes at each elevation at which Bots can enter or exit the ramp. Bot Lanes connect one side to the transit deck at the top of the ramp and another side to each storage level within the storage area. A Bot descending a ramp may enter the ramp only at the top of the ramp from the transit deck and may exit the ramp to any storage level within the zone (with no reverse maneuver required at any time). address) as seen in Figure 37D. A robot descending the ramp can enter the ramp only from one of the storage levels and can exit the ramp only at the top of the ramp to the transit deck (without requiring reversal in either direction). ). The spacing (distance between lanes) is the same as the aisle width except in the ramp zone near the ramp lanes, where the spacing increases. There is a space in the Bot lane immediately adjacent to each of the four ramp lanes, which allows the gear wheel axles of a Bot ascending or descending the ramp to pass through the lane.
Transit ramps are structural subassemblies that interconnect multiple floors within a system. Each transit ramp provides a path for robots to move between interconnected transit decks, that is, between floors. Travel on traffic ramps is unidirectional by default to maximize throughput, but can be bidirectional (at lower throughput) if required as a result of an operating problem that prevents travel over one or more traffic ramps. The basic design απηπ Ln/zznz/E/YiAi is the same as hallway ramps, for example, four roller chain ramp lanes with Bot lanes at each entry/exit lift. The configuration differs in that all Bot lanes connect at both ends to transit decks on each floor. Bots ascending or descending a ramp can enter a ramp from any floor and exit on any other floor, reversing the maneuver required at the entrance if descending (except for the upper floor) and at the exit if ascending (except for the lower floor). The upward-moving transit ramps are equipped with charging rails so that the Bots can recharge their supercapacitors as they ascend.
Referring now to Figure 39A, a side view of vehicles with a ramp 1050 is shown. Referring also to Figures 39B through 39E, they show isometric views of vehicles with a ramp 1050. Figure 39A shows an elevation side of ramp 1052 and lane 1054. Robotic vehicles 1056 can enter ramp 1052 at any level and exit ramp 1052 at any level. Figure 39A shows only the inlet on the lower level and the outlet on the upper level. Figure 39B shows robotic vehicles 1056 climbing "ramp" 1052. In climbing mode, their wheels are retracted "inward" to allow them to rise between the "outer horizontal rails." Its wheel sprockets are extended “outward” to engage the “linearly fixed passive roller chain” on the “ramp.” Figure 39C shows a close-up of the robotic vehicle 1056 climbing a ramp 1052. A break 1058 in the outer horizontal rail 1054 allows the pinion shaft 1060 to pass therethrough. Here, a completely passive rail and ramp system is achieved with no switches or moving parts in the structure. Figure 39D shows the robotic vehicle 1056 in the area without a ramp. In the non-ramp zone, the robotic vehicle 1056 is driven with wheels and sprockets inward on the inner horizontal rail to make the robotic vehicle 1056 as narrow as possible to reduce the storage footprint. When a robotic vehicle 1056 passes through an unclimbing “ramp zone,” it extends its wheels “outward” to climb onto the “outer horizontal rail” that is mounted to the width of the robotic vehicle 1056 with the wheels “inward.” Figure 39E shows robotic vehicle 1056 that has just exited the ramp above the upper level. Robotic vehicle 1060 is delivering a basket to a passive storage location adjacent to the “internal horizontal lane.” Referring also to Figures 40A to 40D, they show schematic side views of wheels with pinions 1080 coupling to a ramp. Here, the buttress 1082 engages the buttress rail 1084 while the chain 1086 is engaged by the sprocket 1088. Figures 40A and 40B show the initial engagement where a rubber support may be provided to allow engagement of the chain and limit the coupling wear. Figures 40C and 40D show further progress up the ramp.
BTS – Active Ramp Alternative
The active ramps also use four roller chain ramp rails that are engaged by gear wheels on the Bots. Figures 38A through 38D show side, end and top views of a vehicle with a ramp 1020. Here, the vehicle 1022 climbs or descends the ramp 1024. The Figure shows the alternative to the passive ramp configuration. In this case, the ramps include switches 1026 that can be operated by the robot or operated with motors located on the ramps. The motors are commanded by the απηπ Ln/zznz/E/YiAi robot locally or a central Materials Control System (MCS). Here, the ramp lanes are active rather than passive: at each ramp entry and exit point there is a mechanism that can change the position of any of the multiple segments to control the path the vehicle will take when the gear wheels engage. attach to those segments. This ramp design simplifies and reduces the cost of the robot compared to the passive rail design, but adds complexity and cost to the ramps; While typical applications will favor the passive lane mode, applications that require little storage but high performance may be favored by the active lane.
T-Bots
T-Bots are vehicular robots that have a roughly rectangular chassis and body panels. By way of example, Figures 25A, 25B and 25C show side, top and end views respectively of the vehicle or Basket Bot "T-Bot" exemplary 660. A T-Bot may have an on-board control computer system, including a wireless LAN interface (802.11x) to communicate with the CCS. A T-Bot can have detectors as required for localization, navigation, payload transfer, etc. Figure 33 shows a partial side view of the vehicle actuator or Basket transfer mechanism 900. A T-Bot may have a Basket transfer mechanism 900 by means of which the Bot moves P-Baskets or O-Baskets between its cargo bay. and Basket placement positions in the TSS, in the workstations, or in the I/O Interface. As an alternative to Basket sliding, the robotic vehicle can be provided with a mount that allows the Basket to be lifted. Here, Figure 33 shows a side elevation of a Telescopic Basket that is extended and raised/lowered using a drive motor. The sliding stages are extended using an endless belt or cable anchored in preceding stages. The first stage of motion follows a chain actuator with parallel elliptical profile bearings to provide lifting and lowering with the stage fully extended to the left or right. Referring also to Figures 34A and 34B, they show isometric views of the exemplary vehicle 930 with the Basket transfer mechanism 900 extended. Figure 34A shows the robotic vehicle serving as a P-Bot or O-Bot with linear slide extension rails that may or may not elevate. Similarly, Figure 34B shows a bottom view of a robotic vehicle acting as a P-Bot or O-Bot. A swivel-mounted wheel on the rear of robotic vehicle that allows steering on the deck, for example when not in a rack system or on the ramp. Here, the robot loads Baskets on board by extending the transfer mechanism to either side of the robot (ambidextrous), engaging the target Baskets, and then pulling the Basket on board by retraction. Additionally, the Bot unloads Baskets by extending the mechanism (which is already engaged with the Baskets) to either side to place the Basket in the target location, releasing the Basket, and then retracting the mechanism. The Bot can slide the Basket across a support surface or lift the Basket prior to retraction/extension, which would eliminate the need for a support surface under the Basket. Referring also to Figures 31A and 31B, they show side and end views respectively of the vehicle 840. Also referring to Figures 31C and 31D, they show isometric views of the vehicle 840. Figure 31A shows an elevation view of the robotic vehicle 840 showing the wheels 842, pinions 844 and Basket 846. The electronic devices and ultracapacitors 848 απηπ Ln/zznz/E/YiAi for energy storage are visible at the top left . Basket 846 is pushed/pulled into the magazine using drive bands 848 with flaps 850 as shown.
Referring now to Figure 32, there is shown a partial isometric view of the vehicle drive wheel/pinion assembly 870. Here, the solid pinion shaft 872 is contained within the hollow wheel shaft 874 contained within the drive shaft. hollow 876. The shafts are registered and separated by an IGUS polymer bushing to allow axial movement. Drive shaft 876 is supported by flange bearing 878 and driven by toothed pulley 880 shown. The end of the pinion and wheel shafts are supported by the thrust bearing which is extended or retracted independently. Extension and retraction can be actuated by union, spring return cable or pneumatic actuators. Each robotic vehicle has four driven wheel assemblies, each assembly having a cylindrical travel wheel, mounted to a hollow drive shaft that is slide-mounted to an actuator. After actuation, the axle and wheel are extendable and retractable between two positions (retracted position and extended position). Referring now to Figures 30A through 30B, isometric views of exemplary vehicle 810 are shown. Those Figures show four states of the wheels and pinions of the robotic vehicle: Figure 34A shows wheels in, pinions in, Figure 34B shows wheels out, pinions in, Figure 34C shows wheels in, pinions out, Figure 34D shows wheels in, sprockets out. All four states are required as will be described with respect to ramps. When passing through a ramp area without climbing the state is wheels “out” to engage the “outer horizontal rail”. When entering the “up ramp” the state is wheels “out” when approaching the “ramp zone”, once the first wheel passes the first ramp the sprockets extend “out”, once the As the vehicle begins to climb, the wheels retract “inward” to allow the robotic vehicle to remain between the “outer horizontal rails.” When climbing or descending a ramp the status is Wheels “in”, sprockets “out”. When exiting an “up ramp” and climbing just above the lane to exit the wheel-extended “out” state, descend the ramp onto the “outer horizontal lane,” and ascend onto the “horizontal lane,” retract the sprockets “in” to proceed forward. When entering the “down ramp” the state is wheels “out” when approaching the ramp zone, once the first wheel passes the first ramp, the sprockets extend “out”. When the robotic vehicle returns up the “outer horizontal rail” and climbs the ramp backwards the wheel retracts “in” and the robotic vehicle proceeds down the ramp. When exiting a “down ramp” and when the robotic vehicle approaches the level to exit, the wheels are extended “outward” and land on the “outer horizontal rail.” Once on the rail, the sprockets retract “inwards.” Once out of a “ramp zone” the wheels retract “inward.”
Referring also to Figures 29A through 29C, there are shown views of exemplary alternative vehicle drive embodiments 780 having parallel axles as opposed to concentric axles. Drive 780 has a drive motor with an encoder and brake 782, first pinion and bearing driven shaft 784, and second pinion and bearing driven shaft 786.
Modality A of direct placement workstation απηπ Ln/zznz/E/YiAi
Referring now to Figures 20A and 20B, they show elevation and plan views respectively of an exemplary workstation 480. The drop-in workstation 480 is a multi-order picker-to-basket workstation design. in which multiple O Baskets 482 that are filled concurrently remain stationary on holding shelves 486 and the collector 484 moves toward the target basket at each placement. This mode may be simpler than workstation mode B described below, but requires more movement on the part of the collector, resulting in lower throughput.
The workstation subsystem has basket holding shelves 486. There is a basket holding shelf on each side of the collector 484, immediately after the collector, with rear access by the O-Bots 488. Empty O Baskets are placed on containment shelves by the O-Bots, they remain there until they are filled, and then they are removed by the O-Bots. A P-Bot tilt attachment 490 is shown as an attachment following a trajectory immediately in front of the picker 484. Here, the P-Bots 492 are sequentially directed toward the attachment 490 from the side, stopping at position for the picker to remove the designated number of pieces from the onboard basket P, then exit the fixture from the other side and leave the workstation. The attachment tilts the Bot approximately 30 degrees toward the picker 484 to make it easier for the picker 484 to reach and remove parts from the onboard P-basket 494. The tilt attachment and possibly the tail rail on the attachment are equipped with the rail. charging so that the Bots can recharge the supercapacitors on each trip to a workstation. A machine vision subsystem (MVS) 496 is shown mounted directly above the Bot tilt attachment where there is a camera assembly (including lighting when required) looking down over the basket P in the picking position, and Above each containment shelf are camera mounts that look down onto the baskets or onto the shelf. The cameras are connected to the vision computer that is programmed to track the picker's hand movements and analyze the contents of the target baskets both before and after the pick/place transaction to validate the accuracy of the pick. Here, collectors can use gloves to facilitate the process. The white illuminators shown mounted in conjunction with each camera assembly are a light source, for example, a laser or concentrated light that can be directed anywhere within any basket within the field of view of the camera, the purpose of which is to assist the operator to accurately execute the pick/place but illuminating both the white SKU location that will be picked and the white location within the white OR basket in which each picked piece is to be placed. A picker interface is shown where the workstation control computer can receive information from and provide information to the picker: 1) display screen 498 showing the remaining number of required pieces to be picked from the blank basket P, the which decreases with each pick/place cycle; 2) the headset 500 worn by the collector, which includes headphone speakers through which it can receive synthesized voice input (and optionally listen to background music) and a microphone through which it can provide input to the computer via its recognition capability voice. A workstation control computer (WCC) handles all processes and activities associated with picking parts at the workstation. This may be a logical απηπ Ln/zznz/E/YiAi computer that functions as part of the CSS or alternatively a separate physical computer that is dedicated to controlling one or more workstations and communicates with the CSS over a network (wired or wireless ). The WCC interfaces with the collector, machine vision subsystem, target illuminators, and with the P-Bots when they are operating under the control of the WCC; When a P-Bot arrives at the entrance to do the workstation, the CCS passes control of that Bot to the WCC.
The workstation process can have the following steps starting with a P-Bot already on the tilt fixture and O Baskets on the connecting shelves which are repeated recursively until there are no more line items that need to be delivered to the workstation. The WCC activates two white illuminators to illuminate both pick and place locations. The MVS captures the above image of the P Basket and the white O Baskets. The WCC displays on the screen both the number of remaining pieces that will be picked by the current order line and a graph showing the target O basket and synthesizes voice input of the same information through the headset. The MVS tracks the movement of the picker's hands during a pick via the camera looking down on the P basket and verifies that the picker is picking the correct SKU; when the hand leaves the picking zone with the picked piece: the MVS captures the ''back'' image of basket P and verifies by comparison with the ''before'' image that at least one piece has been removed from basket P ; The WCC reduces the number of pieces that will be collected on the screen display; If the picked part is the last of a current SKU transaction, the WCS orders the P-Bot out of the tilt fixture, the next P-Bot moves toward the tilt fixture, and all other P-Bots in the pick queue advance a Bot position; Indexing of P-Bots occurs this way while the picker is putting into the O basket, so the picker should never have to wait for a P-Bot to arrive. The MVS follows the movement of the picker's hands during a placement by means of the camera looking down on the target basket O and verifies that the picker places the correct basket O in the correct place: when the empty hand leaves the picking area placement, the MVS captures the “back” image of basket P and verifies by comparison with the “before” image that at least one part has been placed in basket O.
Direct Placement Workstation Mode B:
Referring now to Figures 21A and 21B, they show plan and elevation views respectively of a multiple basket order workstation for exemplary picker 510. The multiple basket order workstation for the picker 510 is shown where the picker 512 remains stationary and the O Baskets 514 are presented to the picker in a sequence that matches the arrival sequence of P Baskets 516, so that there is always just a white O basket in the placement position. Compared to mode A, this design has mechanisms that move the O-Baskets, but require significantly less movement on the part of the picker and may allow for greater throughput of the picker.
The workstation subsystem has basket handling subsystems (THS) 518 that moves the O Baskets to the placement position in sequence to receive pieces collected from P Baskets, including the segmented conveyor 520, a vertical sequencer 522, and two cross transfers 524. Two απηπ Ln/zznz/E/YiAi lanes of the segmented roller conveyor - a “placement lane” 526 and a “return lane” 528 are shown. The placing rail is located to the right after the collector and consists of four segments that move the baskets toward and along the collector. The “entry segment” is where the O-Bots place empty O-Baskets, and each new basket remains in the segment until moving forward to the “available segment.” The “available segment” holds the next basket to receive parts after all placements in the current OR basket on the “placement segment” have been completed. The “placement segment” retains the white basket O into which the picker places the collected pieces. The “withdrawal segment” moves the O Baskets away from the placement segment; each basket is then immediately pushed by the cross transfer 1 onto the return rail of the conveyor. The return lane is located on the opposite side of the picker placement lane and consists of three logical segments that transport O-Baskets in the opposite direction of the placement lane. The “return segment” is a logical segment comprising two physical transport segments that move O Baskets to and then over the resequencing segment; the first segment receives Baskets O from the placement rail via the basket driver 1 and the second segment acts as a regulator for the resequencing segment. The resequencer segment is a logical position in the return lane that is occupied at different times by any of the physical segments within the vertical resequencer. The “output segment” receives full O-Baskets outgoing from the resequencer segment and retains it for collection by the O-Bot. The vertical resequencer is an assembly comprising a motorized frame to which multiple physical transport segment subassemblies are mounted; It moves vertically so that any of its physical transport segments can be aligned with the return transport lane and serve as the resequencer segment. Cross transfers are shown where there are two mechanisms that transfer O Baskets between the two transport lanes, for example by pushing them. Cross transfer 1 moves baskets from the pick-up segment of the put-in lane to the return segment of the return lane. Cross transfer 2 moves baskets from the resequencing segment of the lane back to the available segment of the placement lane. The P-Bot 530 tilt attachment is shown as an attachment aimed immediately at the front of the collector. The 532 P-Bots move sequentially toward the fixture from one side, stop in position for the picker to remove the designated number of pieces from the onboard P basket, then exit the fixture from the other side and exit the station. of work. The attachment tilts the Bot approximately 30° toward the picker to make it easier for the picker to reach and remove pieces from the onboard P basket. The tilt attachment and tail rail leading to the attachment are equipped with charging rails so that the Bots can recharge the supercapacitors on each trip to the workstation. The machine vision subsystem (MVS) 534 is mounted directly above the Bot tilt attachment is a camera assembly (including illumination when required) that looks downward over the P basket 516 in the picking position, and mounted Above the positioning segment is a downward-facing camera assembly over the white O basket in the positioning position. All cameras are connected to the vision computer which is programmed to follow the picker's hand movements and analyzes the contents of target baskets both before and after the pick/place transaction. The white illuminators mounted in conjunction with each απηπ Ln/zznz/E/YiAi camera mount are a light source, for example, laser or focused light that can be directed anywhere within any basket within the camera's field of view. , the purpose of which is to help the operator accurately execute the pick/place by illuminating the location of the target SKU that will be picked and the white spot within the basket OR target in which each picked piece will be placed. The collector interface is provided where the workstation control computer can receive information from and provide information to the collector: 1) display screen 536.
The workstation process may have the following steps starting with the P-Bot already in the tilt attachment and O-Baskets within the THS, including a white O-basket in the placement position) which are repeated recursively until there are no and order lines that have to be delivered to the workstation. The WCC activates two white illuminators to illuminate two pick and place locations. The MVA captures the “previous” image of the P basket and the white O Baskets. The WCC displays on the screen the number of pieces that are to be picked by the current order line and synthesizes voice input of the same information through headphones. The MVS tracks the movement of the picker's hands during a pick via the downward-facing camera above the P basket and verifies that the picker is picking the correct SKU; when the hand leaves the picking area with each piece. The MVA captures the “back” image of basket P and verifies by comparison with the “back” image that at least one part has been removed from basket P. The WCC displays on the screen the number of pieces that will be collected. If this was the final piece of the current SKU transaction, the WCS will exit the tilt fixture, the next P-Bot will enter the tilt fixture, and all other P-Bots in the pickup queue will advance one Bot position; Indexing of P-Bots occurs in this way while the picker is placed in the O basket, so the picker will never have to wait for a P-Bot to arrive. The MVS follows the movement of the picker's hands during a placement by means of the camera looking down on the basket O target and verifies that the picker places the basket O target in the correct place; when the empty hand leaves the placement zone. The MVS captures the “back” image of basket P and verifies by comparison with the “before” image that at least one part has been placed in basket O. If this was the final placement of the current target O-basket in this cycle, meaning the next placement is of a different O-basket, the WCC causes the THS to perform a multi-step, multi-basket motion sequence. The current target O basket is moved forward from the placement segment to the withdrawal segment and simultaneously the O basket in the available segment is moved forward to take place as the current target O basket on the placement segment. Cross transfer 2 moves an OR basket from the resequencer segment to the available segment, or an empty OR basket on the input segment is moved to the available segment. Cross transfer 1 moves the previous blank O basket from the withdrawal segment to receive the portion of the return segment. The O basket or regulating portion of the return segment is moved forward over the now empty resequencer segment (and if the basket has received its last piece, its movement continues over the output segment, where it awaits collection by the O-Bot). . The previous target O basket moves from the receiving portion of the segment back toward the regulating portion of that segment. The vertical resequencer moves vertically when necessary to the position of one of its transport segments απηπ Ln/zznz/E/YiAi as the resequencing segment, either a segment adjacent to the O basket that will be placed over the available segment, if the next ready basket will be the empty OR basket coming from the input segment, an empty segment.
Referring now to Figures 23A, 23B and 23C, they show isometric schematic views respectively of exemplary workstations 570, 570' and 570. Figure 23A shows an exemplary drop-in workstation where operator 572 transfers from Product bot 574 in front of them towards order baskets 576 adjacent to them. Order baskets are deposited and received by Order Bots once the products are deposited. The alternative is for the operator to place the product directly in the order basket that remains in the Order Bot. Matching Product Bot and Order Basket/Order Bot as well as Workstation requires synchronized fulfillment. Figure 23B shows operator 572 with Part Bots 578 to transfer product to them. This indirect placement workstation enables the continuous flow of Product Bots and Part Bots in asynchronous operation. Each Parts Bot moves to the order basket location and deposits the products. Parts Bots can make three or more order basket deliveries using their bins. As an alternative to the Parts Bot, the operator can place the product on a Parts Drone which delivers the product to the order basket. Finally, each parts drone can automatically pick from the retrieved product basket and transport the product directly to the order basket. Figure 23C shows a direct and indirect workstation. Here, robotic vehicles allow the workstation to be flexibly configured and operated on demand. In the above, light beams 580 are displayed above operator 572 indicating pick and place locations. Additionally, a high-resolution camera with machine vision software is located above the workstation to ensure that all operator transfers are correct.
Referring now to Figure 24A there is shown an isometric schematic view of the exemplary automated workstation 600. Referring also to Figure 24B there is shown an isometric schematic view of the exemplary automated workstation 630. As an alternative modality, human workstations can be replaced with automated Product Bot to Order Basket (Direct Placement) or Product Bot to Part Bot (Indirect Placement) workstations. Figure 24A shows a dual portal system 602 for speed and reliability. Each portal has multiple grippers, for example vacuum, articulated and conformable to allow parts to be collected from a wide variety of products. Alternatively, workstations can be configured for each part type. Figure 24B shows a 6-axis articulated robot 632 that can be used as an alternative to the portals shown.
Input/Output Interface “l/O”
The l/O interface is the entry point for Baskets entering the system (Full P Baskets and Empty O Baskets) and the exit point for outgoing Baskets (Empty P Baskets and Full O Baskets). T-Bots transport all Baskets between the I/O Interface and their origin or destination locations within the system. In one aspect, this is also a subsystem having a plurality of bidirectional belt conveyor spurs. Each spur connects a single unidirectional input/output transport line that connects the system to the rest of the facility within which it operates; Incoming baskets flow in on this conveyor line, and outgoing baskets flow out απηπ Ln/zznz/E/YiAi on the same conveyor in the same flow direction. Each Conveyor Spur also comprises two physical belt conveyor segments. An input segment which holds incoming Baskets, located further from the input/output transport line (and closer to the I/O Interface Transit Deck); and an exit segment, which retains the outgoing Baskets momentarily before moving them onto the I/O conveying line. A plurality of Bot Spurs are shown which the T-Bots occupy when executing a Basket exchange transaction. Each Bot spur is built using a pair of Bot rails like those used in ramp modules. The number of Bot Spurs is less than the number of Transporter Spurs, and a Bot Spurs are placed between adjacent Transporter Spurs, so that there is a Transporter Spurs accessible to a T-Bot on each side of each Transport Spurs. Bot, and also each Conveyor Spur except for the two outermost ones that can be accessed from the two Bot Spurs.
The process of Baskets flowing through the I/O interface can have the following steps. Each incoming Basket is transferred from the input/output conveyor line onto an empty Conveyor Spur, which initially arrives onto the Output Segment immediately adjacent to the conveyor line and is then immediately transferred to the Input Segment where it awaits pickup by a T-Bot. Each T-Bot arriving at the I/O Interface (with an outgoing Basket on board) enters an empty Bot Spur adjacent to a Conveyor Spur with a white incoming Basket already waiting in the Entry Segment. The T-Bot first moves to the far end of the Bot Spur, along the waiting Incoming Basket, and unloads the Outgoing Basket that has boarded the Output Segment of the Conveyor Spur. The T-Bot then immediately moves in the opposite direction to align itself with the incoming target Basket, transfers this on board, moves away from the Bot Spur and transports the Basket to its destination (typically a storage location in the TSS). , but occasionally a Collection Workstation). The outgoing Basket in which the T-Bot has been placed on the Output Segment of the Conveyor Spur is transferred at the first opportunity onto the input/output transport line and transported away from the system.
INDIRECT PLACEMENT SYSTEM
With an indirect placement system, parts are transferred from Product Baskets not to O-Baskets but to robots, called Parts Bots (“E-Bots”); The E-Bots are then transported by the T-Bots to the Order Loading Structure (“OLS”) where they transfer the collected parts to the blank O Baskets. The fundamental benefit of decoupling picking from placing in this way is to eliminate workstation specificity for delivery, meaning that any order line can be picked at any workstation. One consequence is that there is considerably less contention by P-Bots for access to workstations compared to the Direct Placement System, since the Bots can take a “path of least resistance”, for example going to the workstation. nearest job and/or the workstation with the fewest number of P-Bots in the collection queue. An even more important advantage, though, is that order delivery latency can be dramatically reduced by assigning multiple order lines assigned to a given Cart OR to multiple T-Bots for parallel delivery to multiple workstations. It will then be possible for the system to deliver a large order in just a few απηπ Ln/zznz/E/YiAi minutes. The main disadvantages of this modality compared to Direct Placement is that it requires more capital investment, and the picking densities will not be as high, which could increase transportation costs, and if orders must be delivered by truck to the customers.
The system includes the same elements/subsystems as the Direct Placement Modality as described above plus two additional ones. “E-Bots,” “portable” robots, each of which have an internal dimensional envelope identical to that of an O-Basket so that they can receive parts collected at Collector workstations just like O-Baskets, retain those pieces during transport by the T-Bots, and transfer the collected pieces to the white O Baskets; E-Bots rely on T-Bots and the transporter for movement. A T-Bot carrying an E-Bot is referred to as an “ET-Bot.”
Components of the Direct Placement System
The P Baskets, O Baskets and TSS can be the same as in the Direct Placement system described above.
Order Loading Structure (“OLS”)
The Order Loading Structure is a shelving structure designed to contain or retain O-Baskets for filling by E-Bots and facilitate the transfer of parts by the E-Bots to those O-Baskets; In the preferred embodiment the OLS is a special section of the TSS. The operating processes, all of which are controlled directly or indirectly by the CCS may be as follows. The flow of P-Baskets to the Picking Workstations can be the same as described with the Direct Placement system above. The flow of OA/OLS Baskets and Shipping to the customer is as follows. Since the OLS is used only for loading O-Baskets and not for buffering, it is kept perceptually full with O-Baskets that are empty, waiting to be filled, or are in the process of being filled, with the exception of intentionally left O-Basket positions. empty to be used for the exchange of Baskets. Full O-Baskets are generally removed immediately once all planned pieces have been received. The CSS initializes the OLS by having the O-Bots fill it with O-Baskets to their maximum planned capacity, leaving a sufficient number of empty O-Basket positions so that there is always an empty O-Basket position reasonably close to any blank filled O-Basket where An O-Bot can place an empty O-Basket on the same trip when removing the full O-Basket. O-Baskets are placed on shelves only on alternating levels so that directly above each Basket is an empty space for an E-Bot to occupy when transferring parts to the O-Basket. Any empty O-Basket in the OLS can be assigned to receive any designated set of order lines, so the CCS generally seeks to distribute the workload evenly by always selecting an O-Basket over the least busy loading lane when a new O-Basket needs to be activated. Once the filling of an active Basket O is completed, an 0Bot is assigned to remove the Basket O from the OLS and transport it to the 1/0 Interface for immediate delivery to the customer or the TSS for immediate storage. Immediately before moving to the target O-Basket location, the O-Bot typically collects an empty O-Basket from either the 1/0 or TSS Interface and places it into the OLS, effectively replacing the filled O-Basket with an empty Basket O to wait for activation. If Basket O removed is απηπ Ln/zznz/E/YiAi basket O, which receives pieces, keeps them in it during transport by the T-Bot, and then transfers the pieces to the white Baskets O. The E-Bot may have a structural frame with the same width and length of a basket OR and height so that the total height of the Bot is the maximum that it can operate within a given system. A control microcomputer may be provided that controls the operations of the robot, with a wireless network interface through which it communicates with the CCS. Rechargeable batteries may be provided that power the operation of the robot. When the E-Bot is not in use, it can be stored in a section of the OLS that provides electrical power to the rechargeable batteries. An array of detectors necessary to perform their required functions may be provided. A plurality of part mobilizers 693, each of which receives and retains parts, and under the control of the robot control microcomputer transfers parts to the Baskets O. All parts placed in a given parts mover can be of the same product and associated with a single order line, but multiple part movers can be used for a single or multiple order lines if necessary. Two modalities of each of the parts mobilizers are described.
Fixed width parts mobilizer
Referring now to Figures 35A, 35B, 36A and 36B, they show isometric views of an exemplary robotic vehicle 960 with fixed width part mobilizers 963. Figure 35A shows a plan view of a robotic vehicle that serves as a Parts bot. The robotic vehicle has recovered a 962 Parts Module to allow it to transform into a Parts Bot. This parts module 962 has three compartments with powered interior hopper doors that allow “parts” to be deposited into order baskets 964. Figure 35B shows a side elevation of the Parts Bot with order basket 964 below. The hopper doors are shown open to allow product to be deposited from parts module 962 to order basket 964. Figure 36A shows another view of the parts module 962 on top of the order basket 964. Figure 36B shows the parts module 962 with the hopper doors visible from above. As opposed to hopper doors, a retractable fabric material can be used to lower the product into the order basket as will be described later. The fixed width parts mobilizer consists of multiple compartments the width of which cannot be modified to conform to the parts placed in it. The floor of each compartment can be opened by an actuator to let the contained parts fall out the bottom and into the basket O target, for example, like bomb bay doors on an airplane. This modality is mechanically simple and suitable in applications where the range of item dimensions is sufficiently limited so that all parts can fit within the fixed widths of the part immobilizers and where the products being moved are not fragile enough so that the fall of the pieces from a maximum height greater than the height of basket O does not damage the falling piece or pieces when they collide within basket 0.
Adjustable width parts mobilizer
Referring now to Figures 26A-28F, the adjustable width part mover consists of a plurality of flexible carriers 692 each of which, in combination with a pair of manipulators, can accommodate a wide variation in part dimensions, and can effect smooth transfer of απηπ Ln/zznz/E/YiAi parts with little or no drop. The 692 file holder resembles a floating file folder in its shape. This is constructed from a rectangular binder sheet of flexible material, the width of which is less than the width of an O basket, the sheet being attached at each end to a rigid hanging bar. Each rigid hanging bar is actually comprised of two separable segments: a hangar segment 694 that is the full width of the E-Bot and provides means for hanging the load carrier, and a handling segment permanently attached to the binder sheet and of the same width. than the folder sheet. The receiving and carrying function of the load carrier is accomplished by placing the two hanging bars together and the ends placed on opposite sides of the E-Bots frame. The flexible binder sheet is then folded to form a bag in which the pieces can be placed, in the same way that materials can be placed in a hanging file in a drawer.
Parts Manipulator
The parts manipulator 698 includes a linear motion device by which the manipulator can move back and forth along the length of the E-Bot above the hanging load carriers. A device for holding and manipulating the handling segment of the hanging bars is shown. A device for rotational movement, such as a motorized roller, attached by a cable to the hanging device, by means of which the manipulator can lower and raise a load carrier. The two manipulators act in concert under the control of the control microcomputer to adjust the width of the opening of each load carrier by performing the following steps as seen in Figures 28A-28F: a) each manipulator places itself on one of the hanging bars of the load carrier and holds the handling segment without detaching it from the handling segment; b) one or both manipulators move linearly along the entire length of the E-Bot, thereby moving one or both of the hanging bars, reducing the size of the carrier opening by moving one toward each other, and increasing the opening by moving them away from each other . The two manipulators acting in concert under the control of the control microcomputer transfer the parts from a load carrier to a basket O by carrying out the following steps: a) each manipulator places itself on one of the hanging bars of the load carrier, holds the handling segment and detaches it from the hanging segment; b) both manipulators move toward each other enough to create space for the hangar segments; c) both manipulators activate the rotational motion means to lower the load carrier towards the basket until the bottom is just above the highest object below the basket; d) then one manipulator reverses the direction of rotation while the other manipulator continues rotation in the same direction, and the manipulators move slowly toward each other. This causes one end of the binder sheet to retract upward and the other to continue moving downward, and the pieces contained in the binder will slide along the binder sheet material and may wobble in place; e) eventually the manipulators will be together and the folder sheet will be completely vertical and at some point the contained pieces will fall out of the carrier and towards basket 0; f) at that point the manipulator will manipulate the lower end of the load carrier and the load carrier will now fully retract towards the manipulators.
Indirect Placement Workstation
Referring now to Figures 22A and 22B, they show elevation and plan views απηπ Ln/zznz/E/YiAi respectively of an exemplary workstation 540. Any type of workstation can be used, for example, drop-in station A or B, although the picker basket version B can provide higher picking throughput and can take advantage of the higher throughput of the P-Bot that is available. becomes possible due to the ability to “any line item on any workstation. The basic operation of the workstation with either modality is essentially the same as with the direct placement modality described above, with the following differences related to the fact that the E-Bots are not tied to any specific customer order until Parts are placed on a carrier to deliver a specific order line. The assignment of order lines to E-Bots and cargo carriers can be essentially arbitrary, so that picked parts will typically be placed on cargo carriers in sequential order, meaning that an E-Bot 542 will have each of its cargo carriers 544 filled one after the other. of the other from each arriving P-Bot until all cargo carriers are filled and the E-Bot is ready to collect 546 and transport to the OLS by means of a T-Bot. Prior to the arrival of each P-Bot at the workstation, the white E-Bot has been instructed by the CSS to place each load carrier opening to a certain width based on the dimensions of the parts that will be placed in the carrier. . The workstation's B-mode vertical resequencer may be essentially inactive during the collection operation under the indirect placement model. Empty E-Bots are placed under the entry segment of the placement conveyor line upon arrival at the workstation and simply proceed through the line until all load carriers have been filled in the placement segment, period. in which it is transferred to the return transport line and passes directly through the resequencing segment to the output segment where it awaits pickup by a T-Bot.
The I/O interface may be the same as with the direct placement system described above. SYSTEM TOPOLOGIES
There are different variations in system topology that can be used for a given system depending primarily on peak performance requirements. Ranging from the simplest to the most complex, they include:
Bi-directional flow, single-ended
Bot workstations and transit structures are located only at one end of the TSS. Since T-Bots enter and exit hallways only at one end, movement within hallways is by definition bidirectional. Since entry and exit points at the workstation level are potential bottlenecks, the number of aisles and the number of workstation levels are factors that determine the performance capacity of a system. That is, the more hallways and more workstation levels there are in a system, the greater the performance capacity of that system. This topology is suitable for applications with low to medium performance requirements.
Double Ended Bidirectional Flow
The workstations and Bot Transit Structures are located at both ends of the TSS with bidirectional movement within corridors. By doubling the number of hallway entry/exit points and the απηπ Ln/zznz/E/YiAi number of workstation levels (assuming they are equal on each side), this topology is suitable for high-throughput applications. This also has the potential to improve productivity because travel times can often be optimized by giving priority assignment to Bots located closer to target SKU locations. This configuration offers a natural expansion path in applications where volume is growing over time.
Double Ended Unidirectional Flow
In applications that require extremely high performance, this topology optimizes the flow of Bot traffic by having all Bots travel in the same direction. Bots always enter hallways at one end of the TSS, traveling the entire length of the hallway and exiting at the other end of the hallway, creating a circular flow that supports an extremely high throughput rate. Additionally, at the exit end of the hallway, the movement of the T-Bots on the Transit Deck can be synchronized so that the Bots staggered in the hallway exit momentarily until a group of them move simultaneously on the Transit Deck. and create a flow of Bots that flows to the workstations located next to the TSS. Bots must travel greater distances than with previous topologies because each trip is at least twice the length of the hallway, but this flow pattern avoids the massive congestion and deadlocks that occur with bidirectional travel at high volumes. extremely high performance.
As used herein, the terms “comprises” and “comprising” are intended to be interpreted as inclusive, not exclusive. As used herein, the terms “exemplary,” “example,” and “illustrative” are intended to mean “serving as an example, case, or illustration” and should not be construed as indicating, or failing to indicate, a preferred configuration. or advantageous in relation to other configurations. As used herein, the terms “about” and “approximately” are intended to cover variations that may exist at the upper and lower limits of ranges of subjective or objective values, such as variations in properties, parameters, sizes and dimensions. In a non-limiting example, the terms “about” and “approximately” mean at, or more than 10 percent or less, or less than 10 percent or less.
In a non-limiting example, the terms “about” and “approximately” mean sufficiently close to what should be considered to be included by one skilled in the art in the relevant field. As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item or result, as would be appreciated by one skilled in the art. For example, an object that is “substantially” circular would mean that the object is completely a circle up to mathematically determinable limits, or nearly a circle as would be recognized or understood by one skilled in the art. The exact degree of permissible deviation from absolute fullness may in some cases depend on the specific context. However, in general, closeness to plenitude will be having some total result as if total plenitude was achieved or obtained. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or almost complete absence of a characteristic, property, state, structure, item or result, as would be appreciated by one skilled in the art.
απηπ Ln/zznz/E/YiAi
Furthermore, as used herein, the terms “horizontal” and “vertical” are used in a manner consistent with their conventional definitions as would be appreciated by one skilled in the art, and as generally illustrated and expanded upon below. For example, in the fields of physics, engineering, and construction, the direction designated as vertical is usually that along which a plumb line hangs in response to the force of gravity. Alternatively, a spirit level that exploits the buoyancy of an air bubble and its tendency to go vertically upward can be used to test horizontality by aligning the bubble in the center between two lines of the level gauge. Stated differently, according to the generally known concept of the flat earth approximation, the earth is notationally a long (effectively infinite) flat surface with a gravitational field at a right angle to the surface. In that framework, the earth's surface is considered horizontal and any line or plane approximately parallel to the earth's surface is also considered horizontal. The direction of the vertical is considered along a line or plane that is normal or orthogonal to the orthogonal plane. Therefore, movement in a horizontal direction (horizontally) is effectively equivalent to displacement across the surface of the earth, for example, movement forward, backward, left, right, etc., to along the ground, while movement in a vertical direction (vertically) is effectively equivalent to movement upward (away from the earth) or downward (into the earth). To the extent that any ambiguity is generated by the specific wording of the foregoing explanations, it is anticipated that such ambiguity may be interpreted and clarified in a manner consistent with conventional interpretations of the terms horizontal and vertical.
Numerous modifications and alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description should be construed as illustrative only and is for the purpose of teaching those skilled in the art how best to carry out the present invention. The details of the structure may vary substantially without departing from the spirit of the invention, and the exclusive use of all modifications that fall within the scope of the attached claims is reserved. Within this specification the embodiments have been described in such a way as to allow a clear and concise specification to be written, but it is intended and will be appreciated that the embodiments may be combined in various ways and separated without departing from the invention. The present invention is intended to be limited only to the extent required by the appended claims and by applicable rules or laws.
It should also be understood that the following claims cover all generic and specific features of the invention described herein, and all statements of scope of the invention which, as a matter of language, can be said to fall within them.
Contents7
62 sheets
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54 members in 8 offices
Priority claims2
| Document | Office | Kind | Date |
|---|---|---|---|
| 201562169615 | United States of America | P | |
| 62169615 | United States of America | – |
Members54
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| CA2988122A1 | Canada | A1 | |
| US2016355337A1 | United States of America | A1 | |
| WO2016196815A1 | World Intellectual Property Organization (WIPO) | A1 | |
| US2017313514A1 | United States of America | A1 | |
| CA3023959A1 | Canada | A1 | |
| WO2017197121A1 | World Intellectual Property Organization (WIPO) | A1 | |
| AU2016270946A1 | Australia | A1 | |
| EP3303188A1 | European Patent Office (EPO) | A1 | |
| JP2018517646A | Japan | A | |
| CN108290685A | China | A | |
| MX2017015460A | Mexico | A | |
| AU2017261797A1 | Australia | A1 | |
| US2019009985A1 | United States of America | A1 | |
| CN109476419A | China | A | |
| EP3455150A1 | European Patent Office (EPO) | A1 | |
| EP3303188A4 | European Patent Office (EPO) | A4 | |
| JP2019518687A | Japan | A | |
| MX2018013753A | Mexico | A | |
| US2019270591A1 | United States of America | A1 | |
| US10435241B2 | United States of America | B2 | |
| US2020031576A1 | United States of America | A1 | |
| EP3650375A1 | European Patent Office (EPO) | A1 | |
| JP2020100507A | Japan | A | |
| WO2020236641A1 | World Intellectual Property Organization (WIPO) | A1 | |
| CN108290685B | China | B | |
| AU2016270946B2 | Australia | B2 | |
| CN113148506A | China | A | |
| AU2021204720A1 | Australia | A1 | |
| US11142398B2 | United States of America | B2 | |
| CN109476419B | China | B | |
| US11203486B2 | United States of America | B2 | |
| US11235928B2 | United States of America | B2 | |
| US2022033183A1 | United States of America | A1 | |
| US2022063910A1 | United States of America | A1 | |
| CN114132678A | China | A | |
| JP7077349B2 | Japan | B2 | |
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| US11365049B2 | United States of America | B2 | |
| JP7143212B2 | Japan | B2 | |
| US2022315333A1 | United States of America | A1 | |
| MX2022014046AThis record | Mexico | A | |
| JP7199968B2 | Japan | B2 | |
| AU2017261797B2 | Australia | B2 | |
| CN113148506B | China | B | |
| AU2021204720B2 | Australia | B2 | |
| MX2023013051A | Mexico | A | |
| AU2023258452A1 | Australia | A1 | |
| EP3303188B1 | European Patent Office (EPO) | B1 | |
| CN114132678B | China | B | |
| JP2024059556A | Japan | A | |
| US12006149B2 | United States of America | B2 | |
| US2024300737A1 | United States of America | A1 | |
| US12151885B2 | United States of America | B2 | |
| US2025051094A1 | United States of America | A1 |
Numbers
- Publication
- 2022014046
- Application
- 2022014046
Titles
- Spanish
- SISTEMA DE ALMACENAMIENTO Y RECUPERACIÓN
Classification
- CPC, 4
- B65G1/04
- B65G1/0492
- B65G1/1378
- B65G1/0478
- IPC, 1
- B65G1 04