STORAGE AND RETRIEVAL SYSTEM

• US 20160355337A1
• Filed: 06/02/2016
• Published: 12/08/2016
• Est. Priority Date: 06/02/2015
• Status: Active Grant

• Current Assignee: Walmart Apollo, LLC (WalMart Inc.)
• Original Assignee: Alert Corporation (WalMart Inc.)
• Inventors: Lert, John, Fosnight, William J.
• Granted Patent: US 10,435,241 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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:

one or more horizontal drives that propel the mobile robot in at least one direction along at least two horizontal dimensions; and

one or more vertical drives that propel the mobile robot in at least one direction along at least one vertical dimension;

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

wherein the mobile robot is configured to propel itself horizontally along levels of the multi-level storage structure, and to propel itself vertically from level to level of the multi-level storage structure using the inclined or vertical tracks of the multi-level storage structure while maintaining a horizontal attitude.

2. The mobile robot of claim 1, further comprising a drive axle to which the one or more horizontal drives and one or more vertical drives are coupled.

3. The mobile robot of claim 2, wherein the drive axle is extendable and retractable to selectively engage or disengage the one or more horizontal drives and one or more vertical drives with a desired track of a horizontal orientation, or with a desired track of an inclined or vertical orientation.

4. The mobile robot of claim 2, wherein the drive axle is extendable and retractable to selectively engage or disengage the one or more horizontal drives and one or more vertical drives with a desired track of a horizontal orientation, or with a desired track of an inclined orientation or vertical orientation, in such a way that enables the mobile robot to select a desired track of the horizontal orientation or a desired track of the inclined or vertical orientation without requiring an active track switch.

5. The mobile robot of claim 1, wherein the one or more horizontal drives comprise one or more wheels.

6. The mobile robot of claim 1, wherein the one or more vertical drives comprise one or more gear wheels.

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

8. 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.

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

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

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

12. The mobile robot of claim 1, comprising means enabling transition between the horizontal tracks and the inclined or vertical tracks at horizontal track and vertical track intersections by selectively driving and positioning the one or more horizontal drives and/or the one or more vertical drives to engage or disengage a desired horizontal track or a desired vertical track.

13. An automated storage-and-retrieval system, comprising:

a multi-level storage structure comprising a plurality of rack modules separated by aisles, each rack module comprising a set of horizontal supports configured to store objects at a plurality of storage levels within each aisle and a set of horizontal tracks associated with each of the storage levels, and at least one set of inclined or vertical tracks disposed between and connecting levels of the multi-level storage structure; and

at least one mobile robot comprising;

one or more horizontal drives that propel the at least one mobile robot in at least one direction along at least one horizontal dimension; and

one or more vertical drives that propel the at least one mobile robot in at least one direction along at least one vertical dimension;

wherein the one or more horizontal drives engage with the set of horizontal tracks of the multi-level storage structure, and the one or more vertical drives engage with the inclined or vertical tracks of the multi-level storage structure; and

wherein the at least one mobile robot propels itself horizontally along the aisles of the multi-level storage structure, and propels itself vertically from level to level of the multi-level storage structure using the inclined or vertical tracks of the multi-level storage structure.

14. The automated storage-and-retrieval system of claim 13, wherein the at least one set of inclined or vertical tracks further comprise moveable segments that selectively engage the one or more vertical drives of the at least one mobile robot by being moved from a non-engaging position to an engaging position.

15. The automated storage-and-retrieval system of claim 13, wherein the at least one set of inclined or vertical tracks are passive and the at least one mobile robot selectively engages the at least one set of inclined or vertical tracks by moving the one or more vertical drives from a non-engaging position to an engaging position.

16. The automated storage-and-retrieval system of claim 15:

wherein the one or more horizontal drives comprise extendable wheels and the one or more vertical drives comprise extendable gear wheels;

wherein the at least one set of inclined or vertical tracks are positioned adjacent to the set of horizontal tracks; and

wherein the at least one mobile robot extends the wheels of the one or more horizontal drives and retracts the gear wheels of the one or more vertical drives when traveling on the set of horizontal tracks, and extends the gear wheels of the one or more vertical drives and retracts the wheels of the one or more horizontal drives when traveling on the at least one set of inclined or vertical tracks.

17. The automated storage-and-retrieval system of claim 13, further comprising at least one picking station contiguous to at least one aisle, wherein at least one of the at least one mobile robot can deliver a stored object to a picker at the at least one picking station,

18. The automated storage-and-retrieval system of claim 13, further comprising at least one horizontal transit deck contiguous to at least two aisles, the at least one horizontal transit deck enabling the at least one mobile robot to enter and exit the at least two aisles from and to the at least one horizontal transit deck, and travel horizontally to any other location also contiguous to the at least one transit deck.

19. The automated storage-and-retrieval system of claim 18, wherein the at least one set of inclined or vertical tracks further comprise moveable segments that selectively engage the one or more vertical drives of the at least one mobile robot by being moved from a non-engaging position to an engaging position.

20. The automated storage-and-retrieval system of claim 18, wherein the at least one set of inclined or vertical tracks are passive and the at least one mobile robot selectively engages the at least one set of inclined or vertical tracks by moving the one or more vertical drives from a non-engaging position to an engaging position.

21. The automated storage-and-retrieval system of claim 20:

wherein the one or more horizontal drives comprise extendable wheels and the one or more vertical drives comprise extendable gear wheels;

wherein the at least one set of inclined or vertical tracks are positioned adjacent to the set of horizontal tracks; and

wherein the at least one mobile robot extends the wheels of the one or more horizontal drives and retracts the gear wheels of the one or more vertical drives when traveling on the set of horizontal tracks, and extends the gear wheels of the one or more vertical drives and retracts the wheels of the one or more horizontal drives when traveling on the at least one set of inclined or vertical tracks.

22. The automated storage-and-retrieval system of claim 18, further comprising at least one workstation contiguous to the at least one horizontal transit deck, wherein at least one of the at least one mobile robot can deliver at least one stored object to an operator at the at least one workstation.

23. The automated storage-and-retrieval system of claim 22, wherein the at least one stored object comprises containers of items and the at least one mobile robot delivers a plurality of containers to the at least one workstation in such a way that the operator can transfer items between the containers.

24. A transfer mechanism, comprising:

at least one flexible load carrier, comprising;

a support frame;

a first horizontal support bar slidably coupled with the support frame;

a second horizontal support bar slidably coupled with the support frame;

a flexible sheet coupled at a first end with the first horizontal support bar and at a second end, opposite the first end, with the second horizontal support bar; and

a handle coupled with the flexible sheet; and

at least one manipulator, comprising;

first and second linear motion motors that propel the first horizontal support bar or the second horizontal support bar linearly along the support frame;

a grasper device adapted to grasp the handle; and

a motorized load carrier, attached by cable to the handle, adapted to extend or retract the cable to lower or raise objects into or out of the at least one flexible load carrier.

25. The transfer mechanism of claim 24, wherein operation of the first and second linear motion motors operates to slide at least one of the first and second horizontal support bars along the support frame to adjust a volume of space available within the at least one flexible load carrier to carry one or more objects.

26. An automated order fulfillment system, comprising:

a multi-level tote storage structure storing one or more totes;

one or more mobile robots configured to;

pick, transport, and place the one or more totes;

propel themselves horizontally across levels of the multi-level tote storage structure; and

propel themselves vertically from level to level within the multi-level tote storage structure using one or more stationary inclined or vertical tracks;

one or more workstations configured to accommodate a picker that transports one or more caches from one of the one or more totes on one of the one or more mobile robots to a put location; and

an input/output interface where product is inducted into the order fulfillment system and where fulfilled orders are discharged from the order fulfillment system.

27. The system of claim 26, wherein the one or more mobile robots are further configured to propel themselves vertically from level to level in the order fulfillment system while maintaining a horizontal attitude.

28. The system of claim 26, wherein the one or more workstations comprise a tilted location in such a way that the tilted location supports a mobile robot.

29. The system of claim 28, wherein the tilted location supports a first mobile robot and wherein a picker transfers one or more caches from the first mobile robot to a second robot located on the tilted location.

30. The system of claim 26, wherein the one or more mobile robots comprise:

a frame chassis;

a tote transfer mechanism coupled to the frame chassis; and

four actuated wheel assemblies coupled to the frame chassis, with each of the four actuated wheel assemblies having a traction wheel and a fixed gear wheel.

31. The system of claim 30, wherein the fixed gear wheel comprises a sprocket gear and the one or more stationary inclined or vertical tracks comprise a chain that engages with the sprocket gear.

32. The system of claim 26, wherein the system implements a direct-put process in which eaches are transferred in a single operation from a product container instance of the one or more totes transported by one of the one or more mobile robots directly into an order container instance of the one or more totes transported by one of the one or more mobile robots.

33. The system of claim 26, wherein the system implements an indirect-put process in which a picked each is placed into a first of the one or more totes transported by one of the one or more mobile robots which transports the picked each to, and then puts it into, an order container instance of the one or more totes transported by one of the one or more mobile robots.

34. The system of claim 26, wherein the one or more stationary inclined or vertical tracks each comprise a counter-rail channel that engages a bearing on the one or more mobile robots to maintain engagement with the vertical tracks.

35. The system of claim 34, further comprising a hinged gate-switch at each entry/exit that enables the bearing on the one or more mobile robots to enter and exit the counter-rail channel when the one or more mobile robots are entering or exiting the one or more stationary inclined or vertical tracks and prevents the bearing on the one or more mobile robots from leaving the counter-rail channel when the one or more mobile robots are not entering or exiting the counter-rail channel.

36. The system of claim 34, wherein the one or more stationary inclined or vertical tracks further comprise a pair of horizontal mobile robot rails positioned between opposing vertical tracks at each elevation at which the one or more mobile robots enter or exit the counter-rail channel, the pair of horizontal mobile robot rails connecting to mobile robot beams of each level and to each transit deck.

37. The system of claim 36, wherein a gap exists in the pair of horizontal mobile robot rails immediately adjacent to each of the vertical tracks at each of the one or more stationary inclined or vertical tracks, sized, dimensioned, and configured to enable passage of fixed gear wheels of the mobile robot therethrough when the mobile robot is ascending or descending in the vertical direction.

38. The system of claim 26, wherein the one or more stationary inclined or vertical tracks further comprise powered charging rails configured to transfer charging energy to the one or more mobile robots while engaged with the one or more stationary inclined or vertical tracks.

39. The system of claim 26, wherein the one or more stationary inclined or vertical tracks comprise switches actuated by either the one or more mobile robots or actuated with motors disposed on the one or more stationary inclined or vertical tracks.

40. The system of claim 26, wherein the one or more stationary inclined or vertical tracks comprise switches controlled by the one or more mobile robots or by a central control system.

41. The system of claim 26, wherein the one or more mobile robots comprise an onboard control computer system, including a wireless communication interface.

42. The system of claim 26, wherein the one or more mobile robots comprise one or more sensors configured to indicate location, navigation, or payload transfers.

43. The system of claim 26, wherein the one or more mobile robots comprise adjustable-width each-handler comprising a plurality of flexible load carriers.

44. A mobile robot, comprising:

a frame chassis;

a transfer mechanism coupled to the frame chassis;

a drive axle;

one or more fixed gear wheels mounted on the drive axle;

one or more cylindrical drive wheels mounted on the drive axle;

wherein the one or more fixed gear wheels are configured to engage with a stationary track in inclined orientation, and the one or more cylindrical drive wheels are configured to travel along a stationary track in horizontal orientation;

and wherein the mobile robot is configured to operate with a stationary track that utilizes switches to direct the mobile robot between a desired stationary track in inclined orientation or a desired stationary track in horizontal orientation.

45. A mobile robot, comprising:

a frame chassis;

a transfer mechanism coupled to the frame chassis;

a drive axle;

one or more fixed gear wheels fixed mounted on the drive axle;

one or more cylindrical drive wheels mounted on the drive axle;

wherein the one or more fixed gear wheels are configured to engage with a stationary track in inclined orientation, and the one or more cylindrical drive wheels are configured to travel along a stationary track in horizontal orientation; and

wherein the drive axle is extendable and retractable to engage or disengage the one or more fixed gear wheels and the one or more cylindrical drive wheels with a desired stationary track of the inclined orientation or a desired stationary track of the horizontal orientation.

46. A mobile robot, comprising:

a frame chassis;

a transfer mechanism coupled to the frame chassis;

a drive axle;

one or more fixed gear wheels mounted on the drive axle;

one or more cylindrical drive wheels mounted on the drive axle;

wherein the one or more fixed gear wheels arc configured to engage with a stationary track in vertical orientation, and the one or more cylindrical drive wheels are configured to travel along a stationary track in horizontal orientation; and

wherein the drive axle is extendable and retractable to engage or disengage the one or more fixed gear wheels and the one or more cylindrical drive wheels with either a track of vertical orientation or a track of horizontal orientation in such a way that enables the mobile robot to select a desired stationary track of the vertical orientation or a desired stationary track of horizontal orientation without requiring an active track switch.

47. An automated order fulfillment system, comprising:

a multi-level tote storage structure for storing one or more totes;

one or more mobile robots configured to;

pick, transport, and place the one or more totes;

move horizontally across levels of the multi-level tote storage structure; and

move vertically between levels from level to level within the multi-level tote storage structure using one or more stationary inclined or vertical tracks;

one or more workstations configured to accommodate a picker that transports one or more caches from one of the one or more totes on one of the one or more mobile robots to a put location; and

an input/output interface where product is inducted into the order fulfillment system and where fulfilled orders are discharged from the order fulfillment system.

48. A mobile robot, comprising:

one or more horizontal drives having wheels that propel the mobile robot in at least one direction along at least one horizontal dimension; and

one or more vertical drives having wheels that propel the mobile robot in at least one direction along at least one vertical dimension;

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

wherein the wheels of the one or more horizontal drives and/or the wheels of the one or more vertical drives are moveable such that the robot can selectively engage with the horizontal tracks and with the inclined or vertical tracks.

49. The mobile robot of claim 48, wherein the wheels of the one or more horizontal drives and the wheels of the one or more vertical drives are coaxial.

50. The mobile robot of claim 48, wherein the wheels of the one or more horizontal drives and the wheels of the one or more vertical drives are on separate axles.

51. A mobile robot, comprising:

horizontal drive means configured to propel the mobile robot on a horizontal track;

vertical drive means configured to propel the mobile robot on an inclined or vertical track;

means enabling transition between the horizontal track and the inclined or vertical track at intersections thereof by selectively driving and positioning the horizontal drive means and/or the vertical drive means to engage or disengage a desired horizontal track or a desired inclined or vertical track.

52. An order vending machine, comprising:

a multi-level container storage structure;

a mobile robot operable within the multi-level container storage structure to store and retrieve containers, the mobile robot having direct access to all container storage locations;

a customer access port;

wherein the mobile robot positions the container for access by a customer at the customer access port.

53. The order vending machine of claim 52, wherein the access port is configurable in such a way that all or only a portion of the container is accessible by the customer at the customer access port.