Automated system for transporting payloads

• US 10,179,700 B2
• Filed: 05/14/2018
• Issued: 01/15/2019
• 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:
  US15/978,423
• Publication Number:
  US 20180257863A1
• Time in Patent Office: 246 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 storage and retrieval system comprising:

autonomous robotic vehicles having a propulsion subsystem;

a multilevel container storage structure having a first group of multilevel storage locations configured to store the containers and a second group of multilevel storage locations configured to store the containers, a space being defined between the first and second groups of multilevel storage locations;

multilevel guides traversing levels of the first and second groups of multilevel storage locations;

a horizontal level, the multilevel guides accessible from the horizontal level by the autonomous robotic vehicles;

a workstation configured to allow a picker to transfer items to and from containers at the workstation;

the propulsion subsystem of the autonomous robotic vehicles comprising;

a set of drive wheels configured to freely steer the autonomous robotic vehicles around the horizontal level to;

maneuver the autonomous robotic vehicles to and from the workstation for the transfer of items to and from containers on the autonomous robotic vehicles, and

maneuver the autonomous robotic vehicles to the space defined between the first and second groups of multilevel storage locations, and

a set of gears configured to engage the multilevel guides when the set of drive wheels maneuver the autonomous robotic vehicles around the horizontal level to the space defined between the first and second groups of multilevel storage locations, the set of gears configured to move the autonomous robotic vehicles between the levels of the multilevel container storage structure upon engaging the multilevel guides.

2. The storage and retrieval system of claim 1, wherein the workstation is positioned on the horizontal level.

3. The storage and retrieval system of claim 1, wherein the workstation comprises a picker-height position above the horizontal level where the picker transfers items to and from the containers.

4. The storage and retrieval system of claim 3, wherein the workstation comprises a ramp between the horizontal level and the picker-height position.

5. The storage and retrieval system of claim 4, wherein the set of drive wheels maneuver the autonomous robotic vehicles between the horizontal level and the picker-height position on the ramp.

6. The storage and retrieval system of claim 4, wherein the ramp tilts the autonomous robotic vehicles toward the picker at the picker-height position.

7. The storage and retrieval system of claim 4, wherein the ramp comprises rails on which the autonomous robotic vehicles travel.

8. The storage and retrieval system of claim 1, wherein the workstation comprises a tilt mechanism for receiving the autonomous robotic vehicles and tilting the autonomous robotic vehicles toward the picker.

9. The storage and retrieval system of claim 1, wherein the horizontal level is one of a plurality of horizontal levels at different levels of the first and second groups of multilevel storage locations.

10. The storage and retrieval system of claim 9, wherein the workstation is one of a plurality of workstations, each workstation configured to allow a picker to transfer items to and from containers at the workstation, different workstations being positioned on different horizontal levels.

11. The storage and retrieval system of claim 1, wherein the set of gears are coaxial with the set of drive wheels.

12. The storage and retrieval system of claim 1, wherein the multilevel guides comprise resistance features engaged by the set of gears.

13. The storage and retrieval system of claim 1, wherein the picker of the workstation comprises an autonomous robotic picker for transferring the items to and from the containers in the autonomous robotic vehicles.

14. The storage and retrieval system of claim 1, further comprising a central control system configured to control the propulsion subsystem to:

maneuver the autonomous robotic vehicles to and from the workstation for the transfer of items to and from containers on the autonomous robotic vehicles,

maneuver the autonomous robotic vehicles to the space defined between the first and second groups of multilevel storage locations, and

cause engagement of the set of gears with the multilevel guides.

15. The storage and retrieval system of claim 1, wherein the autonomous robotic vehicles engage the multilevel guides from a plurality of positions on the horizontal level.

16. The storage and retrieval system of claim 1, wherein the horizontal level comprises a first horizontal level, and wherein the autonomous robotic vehicles engage a multilevel guide on the first horizontal level to access a second horizontal level above or below the first horizontal level.

17. The storage and retrieval system of claim 1, further comprising horizontal rails at levels of the multilevel container storage structure, the set of drive wheels of the autonomous robotic vehicles further configured to move the autonomous robotic vehicles along the horizontal rails at the levels of the multilevel container storage structure.

18. The storage and retrieval system of claim 17, wherein the autonomous robotic vehicles engage a multilevel guide to move between and access the horizontal rails on different levels.

19. The storage and retrieval system of claim 17, wherein the autonomous robotic vehicles are configured to move along the horizontal rails on a level to access storage locations of the first and second groups of multilevel storage locations on either side of the autonomous robotic vehicles.

20. The storage and retrieval system of claim 1, wherein the multilevel guides comprise a track engaged by the set of gears on the of the propulsion subsystem to enable the autonomous robotic vehicles to move between the levels of the multilevel container storage structure.

21. The storage and retrieval system of claim 1, wherein the multilevel guides comprise a chain engaged by the set of gears on the of the propulsion subsystem to enable the autonomous robotic vehicles to move between the levels of the multilevel container storage structure.

22. A storage and retrieval system comprising:

autonomous robotic vehicles having a propulsion subsystem;

a multilevel container storage structure having a first group of multilevel storage locations configured to store the containers and a second group of multilevel storage locations configured to store the containers, a space being defined between the first and second groups of multilevel storage locations;

multilevel guides traversing levels of the first and second groups of multilevel storage locations;

a horizontal level, the multilevel guides accessible from the horizontal level by the autonomous robotic vehicles;

a workstation on the horizontal level configured to allow a picker to transfer items to and from the containers, the workstation comprising a picker-height position at which containers are presented to the picker, wherein the picker-height position of the workstation is elevated above the horizontal level;

the propulsion subsystem of the autonomous robotic vehicles comprising;

a set of drive wheels configured to freely steer the autonomous robotic vehicles around the horizontal level to;

maneuver the autonomous robotic vehicles to and from the workstation for the transfer of items to and from containers on the autonomous robotic vehicles, and

maneuver the autonomous robotic vehicles to the space defined between the first and second groups of multilevel storage locations, and

a set of gears configured to engage the multilevel guides when the set of drive wheels maneuver the autonomous robotic vehicles around the horizontal level to the space defined between the first and second groups of multilevel storage locations, the set of gears configured to move the autonomous robotic vehicles between the levels of the multilevel container storage structure upon engaging the multilevel guides.

23. The storage and retrieval system of claim 22, wherein the workstation comprises a ramp between the horizontal level and the pick and put positions.

24. The storage and retrieval system of claim 23, wherein the set of drive wheels maneuver the autonomous robotic vehicles between the horizontal level and the pick and put positions on the ramp.

25. The storage and retrieval system of claim 23, wherein the ramp tilts the autonomous robotic vehicles toward the picker at the pick and put positions.

26. The storage and retrieval system of claim 22, wherein the workstation comprises a tilt mechanism for receiving the autonomous robotic vehicles and tilting the autonomous robotic vehicles toward the picker.

27. The storage and retrieval system of claim 22, wherein the picker of the workstation comprises an autonomous robotic picker for transferring the items to and from the containers in the autonomous robotic vehicles.

28. The storage and retrieval system of claim 22, wherein the autonomous robotic vehicles engage the multilevel guides from a plurality of positions on the horizontal level.

29. The storage and retrieval system of claim 22, wherein the horizontal level comprises a first horizontal level, and wherein the autonomous robotic vehicles engage a multilevel guide on the first horizontal level to access a second horizontal level above or below the first horizontal level.

30. The storage and retrieval system of claim 22, further comprising horizontal rails at levels of the multilevel container storage structure, the set of drive wheels of the autonomous robotic vehicles further configured to move the autonomous robotic vehicles along the horizontal rails at the levels of the multilevel container storage structure.

31. The storage and retrieval system of claim 30, wherein the autonomous robotic vehicles engage a multilevel guide to move between and access the horizontal rails on different levels.

32. The storage and retrieval system of claim 30, wherein the autonomous robotic vehicles are configured to move along the horizontal rails on a level to access storage locations of the first and second groups of multilevel storage locations on either side of the autonomous robotic vehicles.

33. The storage and retrieval system of claim 22, wherein the multilevel guides comprise a track engaged by the set of gears on the of the propulsion subsystem to enable the autonomous robotic vehicles to move between the levels of the multilevel container storage structure.

34. The storage and retrieval system of claim 22, wherein the multilevel guides comprise a chain engaged by the set of gears on the of the propulsion subsystem to enable the autonomous robotic vehicles to move between the levels of the multilevel container storage structure.

35. A storage and retrieval system comprising:

autonomous robotic vehicles having a propulsion subsystem;

a multilevel container storage structure having a first group of multilevel storage locations configured to store the containers and a second group of multilevel storage locations configured to store the containers, a space being defined between the first and second groups of multilevel storage locations;

multilevel guides traversing levels of the first and second groups of multilevel storage locations;

a horizontal level, the multilevel guides accessible from the horizontal level by the autonomous robotic vehicles;

a workstation on the horizontal level, the workstation configured to allow a picker to transfer items from a first of the containers to a second of the containers, the first container positioned at a pick position of the workstation, and the second container positioned at a put position of the workstation;

the propulsion subsystem of the autonomous robotic vehicles comprising;

a set of drive wheels configured to freely steer the autonomous robotic vehicles around the horizontal level to;

maneuver the autonomous robotic vehicles to and from the workstation for the transfer of items to and from containers on the autonomous robotic vehicles, and

maneuver the autonomous robotic vehicles to the space defined between the first and second groups of multilevel storage locations, and

a set of gears configured to engage the multilevel guides when the set of drive wheels maneuver the autonomous robotic vehicles around the horizontal level to the space defined between the first and second groups of multilevel storage locations, the set of gears configured to move the autonomous robotic vehicles between the levels of the multilevel container storage structure upon engaging the multilevel guides.

36. The storage and retrieval system of claim 35, wherein the first container includes an item retrieved from a storage location of the multilevel container storage structure subsequent to an order for the item.

37. The storage and retrieval system of claim 36, wherein the second container receives the item at the workstation, the second container then transported to a delivery section of the storage and retrieval system by an autonomous robotic vehicle.

38. The storage and retrieval system of claim 35, wherein the pick and put positions are adjacent to each other in the workstation.

39. The storage and retrieval system of claim 35, wherein the workstation comprises a ramp between the horizontal level and the pick and put positions.

40. The storage and retrieval system of claim 39, wherein the set of drive wheels steer the autonomous robotic vehicles between the horizontal level and the pick and put positions on the ramp.

41. The storage and retrieval system of claim 39, wherein the ramp tilts the autonomous robotic vehicles toward the picker at the pick and put positions.