Automated storage and retrieval system

• US 10,457,484 B2
• Filed: 06/05/2018
• Issued: 10/29/2019
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Symbotic, Llc
• Original Assignee: Symbotic, Llc
• Inventors: Buzan, Forrest, Cyrulik, Michael, Reynolds, Aria, Sirois, Jason S., Sweet, Larry, MacDonald, Edward A., Apgar, Taylor A., Perrault, Timothy, Toebes, Stephen C.
• Primary Examiner(s): Cumbess, Yolanda R
• Application Number:
  US16/000,749
• Publication Number:
  US 20180282064A1
• Time in Patent Office: 511 Days
• Field of Search: None
• CPC Class Codes: B65G 1/0492 with cars adapted to travel in storage aisles
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses

Abstract

An autonomous rover including a frame having a first end and a second end longitudinally spaced from the first end and forming a payload bay, the payload bay being sized to support a pickface, a common active registration surface configured to engage the pickface, and a drive section connected to the common active registration surface, the drive section being configured to variably position the common active registration surface relative to at least one storage shelf of an automated storage and retrieval system to effect placement of the pickface on the storage shelf so that pickfaces are substantially continuously arranged along the at least one storage shelf with a predetermined storage spacing between the pickfaces.

Claims

1. A method comprising:

providing, on an autonomous rover, a frame having a first end and a second end longitudinally spaced from the first end and forming a payload bay, the payload bay sized to support a pickface;

providing at least a first common registration surface, a second common registration surface, and a third common registration surface, each of the at least the first common registration surface, the second common registration surface, and the third common registration surface engaging the pickface supported on payload supports in the payload bay and being distinct and decoupled from the payload supports;

providing a drive section being connected to the at least the first common registration surface, the second common registration surface, and the third common registration surface;

variably positioning, with the drive section, the at least the first common registration surface, the second common registration surface, and the third common registration surface relative to each other and at least one storage shelf of an automated storage and retrieval system so as to justify the pickface in three degrees of freedom to effect placement of the pickface on the at least one storage shelf; and

picking, with an autonomous rover, one or more items from one or more storage locations of the at least one storage shelf to build the pickface.

2. The method of claim 1, wherein the variably positioning the at least the first common registration surface, the second common registration surface, and the third common registration surface effects placement of the pickface on a storage shelf so that pickfaces are substantially continuously arranged along the shelf with a predetermined storage spacing between the pickfaces.

3. The method of claim 1, further comprising providing a controller connected to the drive section and effecting movement, with the controller, of one of the at least the first common registration surface, the second common registration surface, and the third common registration surface so that an average position of the one of the at least the first common registration surface, the second common registration surface, and the third common registration surface relative to the payload bay is substantially coincident with a predetermined position of the pickface within the payload bay.

4. The method of claim 1, further comprising:

providing a controller connected to the drive section;

effecting, with the controller, movement of one of the at least the first common registration surface, the second common registration surface, and the third common registration surface for engagement with the pickface; and

monitoring, with the controller, at least a current value of the drive section to control an engagement for one of the at least the first common registration surface, the second common registration surface, and the third common registration surface with the pickface, wherein the controller determines the engagement force with a Kalman filter.

5. The method of claim 1, wherein

one of the at least the first common registration surface, the second common registration surface, and the third common registration surface includes:

a first movable member disposed at least partly within the pay load bay, and

a second movable member disposed at least partly within the payload bay, the second movable member being opposingly positioned relative to the first movable member, the method further comprising;

moving, with the drive section, the first and second movable members towards and away from each other and together longitudinally as a unit.

6. The method of claim 1, further comprising variably positioning, with the drive section, the at least the first common registration surface, the second common registration surface, and the third common registration surface relative to a global automated storage and retrieval system reference frame.

7. The method of claim 1, wherein variably positioning the at least the first common registration surface, the second common registration surface, and the third common registration surface decouples placement of the pickface from the frame.

8. An autonomous rover comprising:

a frame having a first end and a second end longitudinally spaced from the first end and forming a payload bay, the payload bay being sized to support a pickface;

at least a first common registration surface, a second common registration surface, and a third common registration surface, each of the at least the first common registration surface, wherein each of the second common registration surface, and the third common registration surface is;

configured to engage the pickface supported on payload supports in the payload bay, and

distinct and decoupled from the payload supports; and

a drive section, wherein the drive section is;

connected to the at least the first common registration surface, the second common registration surface, and the third common registration surface, wherein the autonomous rover is configured to pick one or more items from one or more storage locations of the at least one storage shelf to build the pickface, and

the drive section is configured to variably position the at least the first common registration surface, the second common registration surface, and the third common registration surface relative to each other and at least one storage shelf of an automated storage and retrieval system to;

effect picking of one item from the storage location with the autonomous rover holding another item, and

justify the one or more of the one item picked and the other item held in three degrees of freedom, into a common multi-item unit commonly defining the pickface in the payload bay.

9. The autonomous rover of claim 8, wherein the variable positioning of the at least the first common registration surface, the second common registration surface, and the third common registration surface effects placement of the pickface on a storage shelf so that pickfaces are substantially continuously arranged along the shelf with a predetermined storage spacing between the pickfaces.

10. The autonomous rover of claim 8, further comprising a controller connected to the drive section to effect movement of one of the at least the first common registration surface, the second common registration surface, and the third common registration surface so that an average position of the one of the at least the first common registration surface, the second common registration surface, and the third common registration surface relative to the payload bay is substantially coincident with a predetermined position of the pickface within the payload bay.

11. The autonomous rover of claim 8, further comprising:

a controller connected to the drive section to effect movement of one of the at least the first common registration surface, the second common registration surface, and the third common registration surface for engagement with the pickface, the controller being configured to monitor at least a current value of the drive section to control an engagement force of the one of the at least the first common registration surface, the second common registration surface, and the third common registration surface with the pickface; and

wherein, the controller includes a Kalman filter configured to determine the engagement force.

12. The autonomous rover of claim 8, wherein:

one of the at least the first common registration surface, the second common registration surface, and the third common registration surface includes;

a first movable member disposed at least partly within the payload bay, and

a second movable member disposed at least partly within the payload bay, the second movable member being opposingly positioned relative to the first movable member; and

wherein the drive section is configured to move the first and second movable members towards and away from each other and together longitudinally as a unit.

13. The autonomous rover of claim 8, wherein the drive section is configured to variably position the at least the first common registration surface, the second common registration surface, and the third common registration surface relative to a global automated storage and retrieval system reference frame.

14. The autonomous rover of claim 8, wherein the variable positioning of the at least the first common registration surface, the second common registration surface, and the third common registration surface decouples a placement of the pickface from the frame.

15. A method comprising:

providing, on an autonomous rover, a frame having a first end and a second end longitudinally spaced from the first end and forming a payload bay, the payload bay sized to support a pickface;

providing at least a first common registration surface, a second common registration surface, and a third common registration surface, each of the at least the first common registration surface, the second common registration surface, and the third common registration surface engaging the pickface supported on payload supports in the payload bay, the at least the first common registration surface, the second common registration surface, and the third common registration surface being distinct and decoupled from the payload supports;

providing a drive section being connected to the at least the first common registration surface, the second common registration surface, and the third common registration surface;

picking, with the autonomous rover, one or more items from one or more storage locations of the at least one storage shelf to build the pickface; and

variably positioning, with the drive section, the at least the first common registration surface, the second common registration surface, and the third common registration surface relative to each other and at least one storage shelf of an automated storage and retrieval system, to;

effect picking of one item from the storage location with the autonomous rover holding another item, and

justify the one or more of the one item picked and the other item held in three degrees of freedom, the justified items forming a common multi item unit defining the pickface in the payload bay.

16. The method of claim 15, wherein the variably positioning the at least the at least the first common registration surface, the second common registration surface, and the third common registration surface effects placement of the pickface on a storage shelf so that pickfaces are substantially continuously arranged along the shelf with a predetermined storage spacing between the pickfaces.

17. The method of claim 15, further comprising:

providing a controller connected to the drive section; and

effecting movement, with the controller, of one of the at least the first common registration surface, the second common registration surface, and the third common registration surface so that an average position of the one of the at least the first common registration surface, the second common registration surface, and the third common registration surface relative to the payload bay is substantially coincident with a predetermined position of the pickface within the payload bay.

18. The method of claim 15, further comprising providing a controller connected to the drive section, effecting, with the controller, movement of one of the at least the first common registration surface, the second common registration surface, and the third common registration surface for engagement with the pickface, and monitoring, with the controller, at least a current value of the drive section to control an engagement for of the one of the at least the first common registration surface, the second common registration surface, and the third common registration surface with the pickface, wherein the controller determines the engagement force with a Kalman filter.

19. The method of claim 15, wherein

one of the at least the first common registration surface, the second common registration surface, and the third common registration surface includes:

a first movable member disposed at least partly within the pay load bay, and

a second movable member disposed at least partly within the payload bay, the second movable member being opposingly positioned relative to the first movable member, the method further comprising;

moving, with the drive section, the first and second movable members towards and away from each other and together longitudinally as a unit.

20. The method of claim 15, further comprising the variably positioning, with the drive section, the at least the first common registration surface, the second common registration surface, and the third common registration surface relative to a global automated storage and retrieval system reference frame.

21. The method of claim 15, wherein variably positioning the at least the first common registration surface, the second common registration surface, and the third common registration surface decouples placement of the pickface from the frame.