STORAGE, RETRIEVAL AND SORTATION SYSTEM

• US 20140277693A1
• Filed: 03/15/2013
• Published: 09/18/2014
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Intelligrated Headquarters LLC (Honeywell International Inc.)
• Original Assignee: Intelligrated Headquarters LLC (Honeywell International Inc.)
• Inventors: Naylor, John R.
• Granted Patent: US 9,020,632 B2
• Time in Patent Office: Days
• US Class Current: 700/218
• CPC Class Codes: B65G 1/0492 with cars adapted to travel in storage aisles
• CPC Class Codes: B65G 1/065 with self propelled cars

Abstract

A material handling systems provides efficient storage, retrieval and sortation of articles, utilizing a plurality of carts capable of traveling under storage areas with a three dimensional warehouse system and on multiple levels. The carts may convey items from storage to a goods to operator user interface. The carts may function as decoupled sortation units capable of providing sortation at multiple mobile sortation locations, providing vertical sortation. Carts may include conveying surfaces, and sort articles from between carts. Carts may transport more than one article and a plurality of carts may transport a single article.

Claims

1. ) A material handling system for storing and retrieving articles, comprising:

a) a grid comprising

i) a first plurality of first paths defined by a plurality of spaced apart tracks extending in a first direction; and

ii) a second plurality of second paths defined by a plurality of spaced apart tracks extending in a second direction;

b) a plurality of carts configured to selectively travel along said first and second paths;

c) a plurality of storage areas, respective portions of a third plurality of said second paths underlying said storage areas, said storage areas configured to support articles above said respective underlying portions such that said carts may travel along said underlying portions without being impeded by articles held by said storage areas; and

d) a controller in communication with said plurality of carts, wherein said controller comprises at least one processor that executes instructions to cause said carts perform operations, said operations comprising selectively traveling to any of a plurality of locations within said grid, said travel including traveling along respective underlying portions of said second paths to reach destinations not on said respective underlying portions.

2. ) The material handling system of claim 1, wherein said operations comprise causing a first one of said carts to travel from a first path onto a respective underlying portion of said second paths and wait there while a second one of said carts passes on said first path.

3. ) The material handling system of claim 2, wherein said operations comprise causing said first one of said carts to return to said first path after said second one of said carts has passed.

4. ) The material handling system of claim 1, wherein a first plurality of said plurality of carts is configured with a lift configured to engage articles held within said storage area such that said carts may remove such engaged articles from said storage area.

5. ) The material handling system of claim 1, wherein a plurality of said plurality of carts comprises respective conveying surfaces.

6. ) The material handling system of claim 1, wherein said grid comprises a plurality of levels, and said instructions cause a plurality of said carts to travel to locations on more than one level.

7. ) The material handling system of claim 6, wherein said grid comprises at least one third path leading between said levels, and wherein said instructions cause said carts to travel along said third paths when traveling between locations on different levels.

8. ) The material handling system of claim 7, wherein said at least one third path comprises an elevator.

9. ) The material handling system of claim 7, wherein said at least one third path comprises an inclined path.

10. ) A material handling system for storing and retrieving articles, comprising:

a) a grid comprising

i) a first level comprising a first plurality of first paths defined by a plurality of spaced apart tracks extending in a first direction and a first plurality of storage areas;

ii) a second level comprising a second plurality of second paths defined by a plurality of spaced apart tracks extending in a second direction and a second plurality of storage areas; and

iii) at least one third path leading between said first and second level;

b) a plurality of carts configured to selectively travel along said first, second and third paths;

c) a controller in communication with said plurality of carts, wherein said controller comprises at least one processor that executes instructions to cause said carts to perform operations, said operations comprising selectively traveling to locations on said first level and on said second level, and traveling along said at least one third path under said carts own power.

11. ) A material handling system for transporting articles, comprising:

a) a first path and a second path, a portion of said first path overlying a portion of said second path at a first location;

b) at least one first cart configured to travel along said first path;

c) at least one second cart configured to travel along said second path; and

d) a controller in communication with at least said at least one first cart, wherein said controller comprises at least one processor that executes instructions to cause said at least one first cart to perform operations, said operations comprising discharging an article carried by said first cart onto said second cart when said first and second carts are proximal said first location.

12. ) The material handling conveyor of claim 11, wherein said at least one first cart comprises an upper conveying surface, and said article is discharged off of a side of said at least one first cart.

13. ) The material handling conveyor of claim 11, wherein said at least one first cart comprises a bottom which moveable to a position at which said cart has an open bottom such that said article is discharged through said open bottom.

14. ) A material handling system for transporting articles, comprising:

a) a first path;

b) a first cart configured to travel along said first path, said first cart comprising an upper conveying surface;

c) a second cart configured to travel along said first path; and

d) a controller in communication with at least said first cart, wherein said controller comprises at least one processor that executes instructions to cause said first cart to discharge an article carried by said first cart onto said second cart when said first and second carts are proximal each other.

15. ) The material handling system of claim 14, wherein said second cart comprises an upper conveying surface.

16. ) A controller for controlling a material handling system comprising a grid comprising a first plurality of first paths defined by a plurality of spaced apart tracks extending in a first direction;

and a second plurality of second paths defined by a plurality of spaced apart tracks extending in a second direction;

a plurality of carts configured to selectively travel along said first and second paths; and

a plurality of storage areas, respective portions of a third plurality of said second paths underlying said storage areas, said storage areas configured to support articles above said respective underlying portions such that said carts may travel along said underlying portions without being impeded by articles held by said storage areas;

wherein said wherein the controller comprises at least one processor that executes instructions to cause said carts to selectively travel to any of a plurality of locations within said grid, said travel including traveling along respective underlying portions of said second paths to reach destinations not on said respective underlying portions.

17. ) The controller of claim 16, wherein said operations comprise causing a first one of said carts to travel from a first path onto a respective underlying portion of said second paths and wait there while a second one of said carts passes on said first path.

18. ) The controller of claim 17, wherein said operations comprise causing said first one of said carts to return to said first path after said second one of said carts has passed.

19. ) A controller for controlling a material handling system comprising a grid comprising a first level comprising a first plurality of first paths defined by a plurality of spaced apart tracks extending in a first direction and a first plurality of storage areas;

a second level comprising a second plurality of second paths defined by a plurality of spaced apart tracks extending in a second direction and a second plurality of storage areas; and

at least one third path leading between said first and second level;

a plurality of carts configured to selectively travel along said first, second and third paths;

wherein the controller comprises at least one processor that executes instructions to cause said carts to perform operations, said operations comprising selectively traveling to locations on said first level and on said second level, and traveling along said at least one third path under said carts own power.

20. ) A controller for controlling a material handling system comprising a first path and a second path, a portion of said first path overlying a portion of said second path at a first location;

at least one first cart configured to travel along said first path;

at least one second cart configured to travel along said second path;

wherein the controller comprises at least one processor that executes instructions to cause said at least one first cart to perform operations, said operations comprising discharging an article carried by said first cart onto said second cart when said first and second carts are proximal said first location.

21. ) A controller for controlling a material handling system comprising a first path, a first cart configured to travel along said first path, said first cart comprising an upper conveying surface, a second cart configured to travel along said first path, the controller comprises at least one processor that executes instructions to cause said first cart to discharge an article carried by said first cart onto said second cart when said first and second carts are proximal each other.