Automated system for transporting payloads

• US 10,435,242 B2
• Filed: 01/31/2017
• Issued: 10/08/2019
• 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:
  US15/421,208
• Publication Number:
  US 20170137222A1
• Time in Patent Office: 980 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. An automated warehouse storage system, comprising:

a multilevel storage array with storage distributed along multiple aisles, wherein each aisle has a set of storage levels and each level has storage locations distributed along the aisle;

an inter-aisle floor that spans at least two aisles of the multiple aisles and is configured for robotic vehicles to move along the inter-aisle floor on a first traction drive of the robotic vehicles;

a guideway network extending through the multilevel storage array and configured for robotic vehicles to move along the guideway network within the multilevel storage array, the guideway network comprising;

a set of guideway levels extending in at least one aisle of the multiple aisles and disposed so that each guideway level of the set of guideway levels is at a different one of the storage levels and the robotic vehicles on a respective guideway level can access the storage locations distributed along a respective aisle on the first traction drive of the robotic vehicles; and

a vertical transition guideway disposed within the at least one aisle connecting one guideway level with another different guideway level, the vertical transition guideway including a track configured to enable a robotic vehicle to move vertically on a second traction drive of the robotic vehicles, different than the first traction drive, within the vertical transition guideway;

a controller configured to control locomotion of the robotic vehicles by the first and second traction drives along either the inter-aisle floor, a guideway level or the vertical transition guideway.

2. The automated warehouse storage system of claim 1, wherein the one guideway level belongs to the set of guideway levels and the another different guideway level belongs to another set of guideway levels.

3. The automated warehouse storage system of claim 1, wherein the vertical transition guideway communicably connects each of the set of guideway levels to the inter-aisle floor forming a common vertical transition guideway connecting the inter-aisle floor and each guideway level, enabling robotic vehicles to move between the inter-aisle floor and guideway levels that are connected to the vertical transition guideway.

4. The automated warehouse storage system of claim 1, further comprising a switch between at least one of the guideway levels and the vertical transition guideway.

5. The automated warehouse storage system of claim 1, further comprising a robotic vehicle moving on each guideway level that moves along the aisle to the storage locations.

6. The automated warehouse storage system of claim 1, wherein the robotic vehicle is self-guided and configured to operate with or without rail-guidance.

7. An automated warehouse storage system, comprising:

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

an inter-aisle floor that spans at least two of the multiple aisles;

one or more robotic vehicles comprising horizontal and vertical traction drives configured to move along the at least one inter-aisle floor and along a guideway network extending throughout the multilevel storage array;

a set of horizontal guideway levels of the guideway network extending in at least one aisle of the multiple aisles and disposed so that each guideway level of the set of guideway levels is at a different one of the storage levels, the horizontal guideway levels comprising horizontally extending rails configured to allow the one or more robotic vehicles access to the storage locations along a respective aisle by traversing the horizontally extending rails by the horizontal traction drive;

a vertical transition guideway disposed within the at least one aisle connecting one guideway level with another different guideway level, the vertical transition guideway comprising vertically extending rails configured to allow the one or more robotic vehicles access to the storage locations on different levels by traversing the vertically extending rails by the vertical traction drive, the vertically extending rails intersecting the horizontally extending rails within the at least one aisle, and the one or more robotic vehicles transitioning from use of the vertical drives to the horizontal drives as the one or more robotic vehicles transition from a vertical transition guideway to a horizontal guideway level;

a controller controlling access by the one or more robotic vehicles to the guideway levels, the controller configured to control a robotic vehicle to move along a horizontal guideway level or the vertical transition guideway by selecting the horizontal guideway level or vertical transition guideway when the robotic vehicle reaches an intersection between the horizontally extending rails and the vertically extending rails.

8. The system of claim 7, further comprising the vertical transition guideway communicably connecting each of the set of guideway levels to the inter-aisle floor forming a common vertical transition guideway connecting the inter-aisle floor and each guideway level, enabling the one or more robotic vehicles moving between the inter-aisle floor and guideway levels that are connected to the vertical transition guideway.

9. The system of claim 7, wherein the controller controlling access comprises the controller activating a switch between at least one of the guideway levels and the vertical transition guideway.

10. The system of claim 7, wherein the one or more robotic vehicles are self-guided and operates with or without rail-guidance.

11. An automated warehouse storage system, comprising:

a storage array having multiple levels, the storage array comprising;

storage distributed along multiple aisles, wherein each aisle has a set of storage levels and each level comprising a first set of rails and storage locations distributed along the aisle;

at least one inter-aisle support platform that spans at least two of the multiple aisles and is configured for robotic vehicles to move along the at least one inter-aisle support platform; and

at least one zone of vertical space comprising a vertical transition interconnecting levels of the multiple levels of the storage array, the vertical transition comprising a second set of rails, the first set of rails intersecting the second set of rails within each aisle;

at least one robotic vehicle comprising a propulsion subsystem with at least one electric motor and transmission mechanisms enabling horizontal travel along the at least one inter-aisle support platform, the first set of rails of each level and the second set of rails of the vertical transition;

a central control system (CCS) managing operation of the automated warehouse storage system;

wherein the CCS controls movement of the at least one robotic vehicle by assigning the at least one robotic vehicle to move totes to and from locations within the storage array, including assigning the at least one robotic vehicle to travel vertically between the multiple levels and horizontally across the at least one inter-aisle floor of the multiple aisles of the storage array; and

wherein the respective aisle comprises two or more of the at least one zone of vertical space.

12. The automated warehouse storage system of claim 11, wherein the CCS controls a traffic-control function to prevent collisions between each of the at least one self-guided robot.

13. The automated warehouse storage system of claim 11, wherein the vertical transition of the at least one vertical zone comprises a ramp.

14. The automated warehouse storage system of claim 11, wherein the vertical transition of the at least one vertical zone comprises a ramp, the at least one robotic vehicle comprises gear devices disposed on drive axles, and the gear devices engage with complementary resistance features built into the ramp.

15. The automated warehouse storage system of claim 11, wherein the vertical transition of the at least one vertical zone comprises a ramp at a steep angle of incline set to reduce loss of space for storage.

16. The automated warehouse storage system of claim 11, further comprising a switch between the at least one of the multiple levels and the vertical transition of the at least one zone of vertical space.

17. The automated warehouse storage system of claim 11, wherein the vertical transition communicably connects each level of the multiple levels to the at least one inter-aisle floor forming a common vertical transition connecting the at least one inter-aisle floor and each level so that when the robotic vehicle moves between the at least one inter-aisle floor and each level the robotic vehicle moves along the common vertical transition.

18. The automated warehouse storage system of claim 11, further comprising at least one picking station.

19. The automated warehouse storage system of claim 18, wherein the at least one robotic vehicle moves to and from the at least one picking station delivering and retrieving totes to and from the at least one picking station.

20. The automated warehouse storage system of claim 11, wherein the at least one robotic vehicle is self-guided, travels bi-directionally, and turns.

21. The automated warehouse storage system of claim 20, wherein the at least one robotic vehicle operates with or without rail-guidance.

30. The system of claim 21, wherein the at least one robotic vehicle is self-guided, travels bi-directionally, and turns.

31. The system of claim 30, further comprising the at least one robotic vehicle operating with or without rail-guidance.

22. An automated warehouse storage system comprising:

a storage array having multiple levels, the storage array comprising;

storage distributed along multiple aisles, wherein each aisle has a set of storage levels and each level has storage locations distributed along the aisle;

at least one inter-aisle floor that spans at least two of the multiple aisles and is configured for robotic vehicles to move along the at least one inter-aisle floor; and

at least one zone of vertical space comprising a vertical transition disposed within the respective aisle and interconnecting levels of the multiple levels of the storage array;

at least one robotic vehicle comprising a propulsion subsystem with at least one electric motor and transmission mechanisms, the at least one robotic vehicle configured to travel horizontally along the at least one inter-aisle floor, horizontally along each level and vertically from level to level of the multiple levels via the vertical transition;

a central control system (CCS) managing operation of the automated warehouse storage system;

the CCS controlling movement of at least one robotic vehicle by assigning the at least one robotic vehicle to move totes to and from locations within the storage array, including assigning the at least one robotic vehicle to travel vertically between the multiple levels and horizontally across the at least one inter-aisle floor of the multiple aisles of the storage array; and

the at least one robotic vehicle configured to move totes to and from locations within the storage array by traveling vertically between the multiple levels and by traveling horizontally across the at least one inter-aisle floor of the multiple aisles of the storage array; and

wherein the vertical transition of the at least one vertical zone comprises a ramp.

23. The system of claim 22, further comprising the at least one robotic vehicle moving along the at least one inter-aisle floor without requiring rail-guidance.

24. The system of claim 22, further comprising the CCS controlling a traffic-control function and preventing collisions between each of the at least one self-guided robot.

25. The system of claim 22, wherein the at least one robotic vehicle comprises gear devices disposed on drive axles, the gear devices engaging with complementary resistance features built into the ramp.

26. The system of claim 22, further comprising the CCS controlling access to the multiple levels by switching a switch between the at least one of the multiple levels and the vertical transition of the at least one zone of vertical space.

27. The system of claim 22, further comprising the vertical transition communicably connecting each level of the multiple levels to the at least one inter-aisle floor forming a common vertical transition connecting the at least one inter-aisle floor and each level enabling the at least one robotic vehicle moving between the at least one inter-aisle floor and each level, the at least one robotic vehicle moving along the common vertical transition.

28. The system of claim 22, further comprising at least one picking station.

29. The system of claim 28, further comprising the at least one robotic vehicle moving to and from the at least one picking station delivering and retrieving totes to and from the at least one picking station.