Storage and retrieval system

• US 10,435,241 B2
• Filed: 06/02/2016
• Issued: 10/08/2019
• Est. Priority Date: 06/02/2015
• Status: Active Grant

• Current Assignee: Walmart Apollo, LLC (WalMart Inc.)
• Original Assignee: Alert Innovation Inc. (WalMart Inc.)
• Inventors: Lert, John, Fosnight, William J.
• Primary Examiner(s): Keenan, James
• Application Number:
  US15/171,802
• Publication Number:
  US 20160355337A1
• Time in Patent Office: 1,223 Days
• CPC Class Codes: B65G 1/0478 for matrix-arrangements
• CPC Class Codes: B65G 1/0492 with cars adapted to travel in storage aisles
• CPC Class Codes: B65G 1/1378 the orders being assembled on fixed commissioning areas remote from the storage areas

Abstract

A system and method for storage and retrieval are provided. The system includes a multi-level storage structure, and mobile robots configured to pick, transport and place one or more tote, container, or object. This system and method can be used in order-fulfillment applications in which one or more workstations accommodate a picker that transports one or more eaches from a tote on one of the autonomous mobile robots to a put location, and an input/output interface induct material into the system and discharge fulfilled orders from the system. The mobile robots are further configured to move from level to level in the multi-level storage structure via inclined or vertical tracks without requiring a vertical lift or vertical conveyor.

Claims

1. A mobile robot, comprising:

at least first and second wheels configured to steer the mobile robot around a horizontal surface; and

at least first and second toothed wheels configured to propel the mobile robot in at least one vertical direction along inclined or vertical tracks of a multi-level storage structure, each of the first and second toothed wheels comprising one of a sprocket, a gear or a pinion;

the first toothed wheel having a retracted position and an extended position and having a same axis of rotation as the first wheel;

the second toothed wheel having a retracted position and an extended position and having a same axis of rotation as the second wheel;

a spacing between the first toothed wheel and the first wheel changeable by transitioning the first toothed wheel between its retracted position and its extended position;

a spacing between the second toothed wheel and the second wheel changeable by transitioning the second toothed wheel between its retracted position and its extended position;

the first and second wheels configured to enable the mobile robot to steer around the horizontal surface to thereby enable the mobile robot to enter and exit either one of at least two aisles of a multi-level storage structure while at least the first and second toothed wheels are in their retracted positions;

the first and second toothed wheels configured to selectively engage with inclined or vertical tracks of the multi-level storage structure, by transitioning from their retracted position to their extended position; and

the mobile robot configured to propel itself horizontally, and to propel itself vertically, while maintaining a horizontal attitude.

2. The mobile robot of claim 1, further comprising a drive axle to which the first wheel and the first toothed wheel are coupled.

3. The mobile robot of claim 2, wherein the drive axle is extendable and retractable to selectively engage or disengage the first toothed wheel with a desired inclined or vertical track of the multi-level storage structure.

4. The mobile robot of claim 2, wherein the drive axle is extendable and retractable to selectively engage or disengage the first toothed wheel with a desired inclined or vertical track of the multi-level storage structure, in such a way that enables the mobile robot to select the desired inclined or vertical track without requiring an active track switch.

5. The mobile robot of claim 1, wherein:

each of the first and second wheels have a retracted position and an extended position;

the first wheel and the first toothed wheel are extendable and retractable independent of one another such that the first wheel can be in its extended position while the first toothed wheel is in its retracted position, and the first wheel can be in its retracted position while the first toothed wheel is in its extended position; and

the second wheel and the second toothed wheel are extendable and retractable independent of one another such that the second wheel can be in its extended position while the second toothed wheel is in its retracted position, and the second wheel can be in its retracted position while the second toothed wheel is in its extended position.

6. The mobile robot of claim 1, further comprising a container transfer mechanism disposed on a chassis of the mobile robot.

7. The mobile robot of claim 1, wherein the mobile robot is configured to be in communication with, and receive control commands from, a centralized control system.

8. The mobile robot of claim 1, wherein the mobile robot comprises an onboard control computer system, including a wireless communication interface.

9. The mobile robot of claim 1, wherein the mobile robot comprises one or more sensors configured to indicate location, navigation, or payload transfers.

10. The mobile robot of claim 1, wherein the mobile robot comprises an adjustable-width each-handler comprising a plurality of flexible load carriers.

11. The mobile robot of claim 1, comprising means enabling transition between horizontal tracks and the inclined or vertical tracks at horizontal track and vertical track intersections by selectively driving and positioning the first and second wheels and/or the first and second toothed wheels to engage or disengage a desired horizontal track or a desired inclined or vertical track.

12. A mobile robot, comprising:

a frame chassis;

a transfer mechanism coupled to the frame chassis;

a drive axle;

one or more toothed wheels mounted on the drive axle, each of the one or more toothed wheels comprising one of a sprocket, a gear or a pinion;

one or more wheels mounted on the drive axle;

wherein the one or more toothed wheels are configured to engage with inclined or vertical tracks of a multi-level storage structure, and the one or more wheels are configured to travel along a horizontal surface;

wherein each of the one or more toothed wheels and the one or more wheels, that are mounted on the drive axle, have a retracted position and an extended position; and

wherein the one or more toothed wheels are extendable and retractable independent of the one or more wheels such that the one or more toothed wheels can be in their extended position while the one or more wheels are in their retracted position, and the one or more toothed wheels can be in their retracted position while the one or more wheels are in their extended position.

13. A mobile robot, comprising:

at least first and second wheels configured to steer the mobile robot around a horizontal surface; and

at least first and second toothed wheels configured to propel the mobile robot in at least one direction along at least one vertical rack, each of the first and second toothed wheels comprising one of a sprocket, a gear or a pinion;

the first toothed wheel having a retracted position and an extended position and having a same axis of rotation as the first wheel;

the second toothed wheel having a retracted position and an extended position and having a same axis of rotation as the second wheel;

the first wheel and the first toothed wheel extendable and retractable independent of one another such that the first wheel can be in its extended position while the first toothed wheel is in its retracted position, and the first wheel can be in its retracted position while the first toothed wheel is in its extended position; and

the second wheel and the second toothed wheel extendable and retractable independent of one another such that the second wheel can be in its extended position while the second toothed wheel is in its retracted position, and the second wheel can be in its retracted position while the second toothed wheel is in its extended position.

14. The mobile robot of claim 13, wherein:

the first wheel and the first toothed wheel are coupled to a first drive axle; and

the second wheel and the second toothed wheel are coupled to a second drive axle.

15. The mobile robot of claim 14, wherein each of the first and second drive axles is extendable and retractable.