Automated system for transporting payloads

• US 10,000,338 B2
• Filed: 09/08/2017
• Issued: 06/19/2018
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Walmart Apollo, LLC (WalMart Inc.)
• Original Assignee: Alert Innovation Inc. (WalMart Inc.)
• Inventors: Lert, Jr., John
• Primary Examiner(s): Logan, Kyle O
• Application Number:
  US15/699,700
• Publication Number:
  US 20170369243A1
• Time in Patent Office: 284 Days
• Field of Search: 700216
• CPC Class Codes: B65G 1/0492 with cars adapted to travel in storage aisles
• CPC Class Codes: B65G 1/065 with self propelled cars
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses
• CPC Class Codes: B65G 1/1378 the orders being assembled on fixed commissioning areas remote from the storage areas

Abstract

An automated warehouse storage system including a multilevel storage array is provided. Each aisle has a set of storage levels and each level has storage locations distributed along the aisle. The guideway network extending through the multilevel storage array is configured for autonomous vehicles to move along the guideway network within the multilevel storage array. The guideway network including an inter-aisle guideway spanning at least two of the multiple aisles and a set of guideway levels extending in an aisle of the multiple aisles and disposed so that each guideway level is at a different one of the storage levels and the vehicles on the guideway level can access the storage locations distributed along the aisle. Each set of guideway levels is connected to the inter-aisle guideway forming a common guideway path so that a vehicle can move between inter-aisle guideway and each guideway level along the common guideway path.

Claims

1. A multilevel storage array for use within an automated warehouse storage system, comprising:

storage locations distributed one or more aisles configured to receive items for storage from a robotic vehicle traveling along the one or more aisles, wherein an aisle has a set of storage levels and each level has the storage locations distributed along the aisle;

a vertical transition guideway disposed within the aisle connecting a first storage level of the set of storage levels with a second level of the set of storage levels; and

a motor-driven vertical drive affixed to the vertical transition guideway for engaging a feature on the robotic vehicle, the motor-driven vertical drive configured to transport the robotic vehicle between the first and second storage levels.

2. The multilevel storage array of claim 1, wherein the motor-driven vertical drive comprises a motor-driven chain.

3. The multilevel storage array of claim 1, wherein the chain is rotatably affixed to the vertical transition guideway.

4. The multilevel storage array of claim 1, wherein the robotic vehicle is inactive during transport by the motor-driven vertical drive and is passively transported by the motor driven vertical drive.

5. The multilevel storage array of claim 1, wherein the feature on the robotic vehicle engaged by the motor-driven vertical drive is a hook.

6. The multilevel storage array of claim 1, further comprising a controller for controlling operation of the motor-driven vertical drive.

7. The multilevel storage array of claim 1, wherein the motor-driven vertical drive is configured to drive the robotic vehicle up and down an inclined ramp.

8. A multilevel storage array for use within an automated warehouse storage system, comprising:

storage locations distributed along one or more aisles configured to receive items for storage from a robotic vehicle traveling along the one or more aisles, wherein an aisle has a set of storage levels and each level has the storage locations distributed along the aisle;

a vertical transition guideway disposed within the aisle connecting a first storage level of the set of storage levels with a second level of the set of storage levels; and

a motor-driven chain drive affixed to the vertical transition guideway, the motor-driven chain drive configured to engage the robotic vehicle and configured to transport the robotic vehicle between the first and second storage levels without reliance on a drive motor in the robotic vehicle.

9. The multilevel storage array of claim 8, further comprising a controller for controlling operation of the motor-driven vertical drive.

10. The multilevel storage array of claim 8, wherein the motor-driven vertical drive is configured to drive the robotic vehicle up and down an inclined ramp.

11. An automated warehouse storage system, comprising:

a multilevel storage array comprising storage distributed along one or more aisles, wherein an aisle has a set of storage levels and each level has storage locations distributed along the aisle;

a guideway network associated with the storage locations;

a vertical transition guideway disposed within the guideway network and connecting a first storage level of the set of storage levels with a second level of the set of storage levels;

a robotic vehicle configured to move along the guideway network, the robotic vehicle comprising a motor configured to move the robotic vehicle horizontally along the first and second storage levels; and

a motor-driven vertical drive affixed to the vertical transition guideway configured to engage a feature on the robotic vehicle, and configured to transport the robotic vehicle between the first and second storage levels.

12. The multilevel storage array of claim 11, wherein the motor-driven vertical drive comprises a motor-driven chain.

13. The multilevel storage array of claim 11, wherein the robotic vehicle is inactive during transport by the motor-driven vertical drive and is passively transported by the motor driven vertical drive.

14. The multilevel storage array of claim 11, wherein the feature on the robotic vehicle engaged by the motor-driven vertical drive is a hook.

15. The multilevel storage array of claim 11, further comprising a controller for controlling operation of the motor-driven vertical drive.

16. A method of moving items around a multilevel storage array comprising storage locations, for storing the items, distributed in rows and columns, the method comprising:

(a) moving the items horizontally along the rows by a robotic vehicle having a motor and a horizontal drive system including wheels for horizontal travel; and

(b) moving the items along the columns, between two or more rows, within the robotic vehicle by a motor-driven vertical drive affixed to the multilevel storage array, the motor-driven vertical drive engaging the robotic vehicle to carry the robotic vehicle between the two or more rows.

17. The method of claim 16, wherein said step (b) of moving the items between two or more rows by the motor-driven vertical drive comprises the step of moving the items between two or more rows by a chain included as part of the motor-driven vertical drive.

18. The method of claim 17, wherein the chain is rotatably affixed to the storage array.