Maintenance access zones for storage and retrieval systems

• US 10,507,988 B2
• Filed: 03/19/2019
• Issued: 12/17/2019
• Est. Priority Date: 12/15/2010
• Status: Active Grant

• Current Assignee: Symbotic, Llc
• Original Assignee: Symbotic, Llc
• Inventors: Cyrulik, Michael, Sullivan, Robert
• Primary Examiner(s): Cumbess, Yolanda R
• Application Number:
  US16/358,506
• Publication Number:
  US 20190210816A1
• Time in Patent Office: 273 Days
• Field of Search: None
• CPC Class Codes: B65G 1/0492 with cars adapted to travel in storage aisles
• CPC Class Codes: B65G 1/06 with means for presenting articles for removal at predetermined position or level B65G1/12 takes precedence
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses
• CPC Class Codes: B65G 2207/40 Safety features of loads, equipment or persons
• CPC Class Codes: B65G 47/883 Fixed stop

Abstract

A maintenance access system for a storage and retrieval system having a storage and retrieval space and automated transport vehicles disposed in the space. The system includes at least one maintenance access control unit associated with a portion of the space, at least one barrier in the space and defining a boundary of the portion of the space and configured to substantially prevent the passage of the vehicles past the at least one barrier, and a controller connected to the control unit, the controller being configured to receive a signal from the at least one control unit for isolating the portion of the space associated with the at least one control unit, where the controller in response to the signal closes the at least one barrier isolating the portion of the space and effects the removal from or shutting down of vehicles within the portion of the space.

Claims

1. A human access system for a storage and retrieval system having a storage and retrieval space and automated transport vehicles disposed in the storage and retrieval space, the human access system comprising:

at least one human access control unit associated with a portion of the storage and retrieval space;

at least one control device located in the storage and retrieval space and defining a boundary of the portion of the storage and retrieval space, the at least one control device being configured to stop the passage of the automated transport vehicles past the at least one control device; and

a controller connected to the human access control unit, the controller being configured to receive a signal from the at least one human access control unit for isolating the portion of the storage and retrieval space associated with the at least one human access control unit;

wherein the controller in response to the signal;

isolates the portion of the storage and retrieval space with the control device that stops automated transport vehicles from entering a human access zone, defined by the portion of the storage and retrieval space, and effects routing of operative automated transport vehicles away from the human access zone; and

stops autonomous transport vehicles within the portion of the storage and retrieval space while allowing continued operation of autonomous transport vehicles in other portions of the storage and retrieval space.

2. The human access system of claim 1, wherein the portion of the storage and retrieval space forms a human access zone including at least one picking aisle of the storage and retrieval system wherein the at least one picking aisle is arranged in a vertical stack of picking aisles.

3. The human access system of claim 1, wherein the portion of the storage and retrieval space forms a human access zone including a transfer deck of the storage and retrieval system, wherein the transfer deck provides the autonomous transport vehicles access to one or more picking aisles and/or one or more multilevel vertical conveyor transfer areas.

4. The human access system of claim 1, wherein the portion of the storage and retrieval space forms a human access zone including a multilevel conveyor transfer area wherein the multilevel conveyor transfer area allows the autonomous transport vehicles to transfer cases between the multilevel vertical conveyor and the picking aisles.

5. The human access system of claim 1, wherein:

the portion of the storage and retrieval space forms the human access zone, the human access zone includes multiple picking aisles arranged in a vertical stack;

wherein the picking aisle at the bottom of the stack includes a floor and the picking aisles above the picking aisle at the bottom of the stack within the human access zone are substantially floorless.

6. The human access system of claim 1, wherein:

the storage and retrieval space includes;

multiple storage levels, each level including picking aisles,

a transfer deck common to each picking aisle, and

multilevel vertical conveyor transfer areas connected to the transfer deck; and

the at least one control device is located at one or more of an end of at least one of;

the picking aisles, an entrance/exit of the multilevel vertical conveyor transfer areas, and portions of the transfer deck.

7. The human access system of claim 6, wherein the at least one control device includes one or more of nets, fences and screens.

8. The human access system of claim 6, wherein the at least one control device comprises at least one motorized control device that is actuated to substantially block the one or more of the end of at least one of:

the picking aisles, the entrance/exit of the multilevel vertical conveyor transfer areas, and the portions of the transfer deck.

9. A method of operating an automated warehouse system comprising:

providing a storage and retrieval space with storage locations;

providing at least one autonomous transport vehicle that travels within the storage and retrieval space;

disposing human access zones, each having at least one human access control unit associated with a portion of the storage and retrieval space;

providing a control device located in the storage and retrieval space and defining a boundary of the portion of the storage and retrieval space, the at least one control device being configured to stop the passage of the automated transport vehicles past the at least one control device; and

signaling, with a controller communicably connected to the control device, a status change of the at least one human access control unit for isolating the portion of the storage and retrieval space associated with the human access control unit;

wherein in response to the signal from the controller, the at least one autonomous transport vehicle within a corresponding human access zone stops while other autonomous transport vehicles outside of the corresponding human access zone continue operation in the storage and retrieval space outside the corresponding human access zone.

10. The method of claim 9, further comprising providing the at least one autonomous transport vehicle with a transfer arm configured to transfer items to and from the storage locations of the storage and retrieval space.

11. The method of claim 9, further comprising transferring case units to and from the storage locations of the storage and retrieval space with the at least one autonomous transport vehicle.

12. The method of claim 9, further comprising providing the at least one autonomous transport vehicle access with a transfer deck, to at least one of one or more picking aisles and one or more vertical lift transfer areas disposed in the storage and retrieval space.

13. The method of claim 9, further comprising transferring items between a vertical lift and the storage locations of the storage and retrieval space with the at least one autonomous transport vehicle at a vertical lift transfer area.

14. An automated warehouse system comprising:

a storage and retrieval space with storage locations;

at least one autonomous transport vehicle that travels within the storage and retrieval space;

human access zones each having at least one human access control unit associated with a portion of the storage and retrieval space;

a control device located in the storage and retrieval space and configured to define a boundary of the portion of the storage and retrieval space, the control device is further configured to stop the passage of the automated transport vehicles past the at least one control device; and

a controller communicably connected to the control device, the controller being configured to signal a status change of the at least one human access control unit for isolating the portion of the storage and retrieval space associated with the human access control unit;

wherein in response to the signal from the controller, the at least one autonomous transport vehicle within a corresponding human access zone stops while other autonomous transport vehicles outside the corresponding human access zone continue operation in the storage and retrieval space outside the corresponding human access zone.

15. The automated warehouse system of claim 14, wherein the at least one autonomous transport vehicle includes a transfer arm configured to transfer items to and from the storage locations of the storage and retrieval space.

16. The automated warehouse system of claim 14, wherein the at least one autonomous transport vehicle is configured to transfer case units to and from the storage locations of the storage and retrieval space.

17. The automated warehouse system of claim 14, wherein the at least one autonomous transport vehicle is configured to access, via a transfer deck, at least one of one or more picking aisles and one or more vertical lift transfer areas disposed in the storage and retrieval space.

18. The automated warehouse system of claim 14, wherein the at least one autonomous transport vehicle is configured to transfer items between a vertical lift and the storage locations of the storage and retrieval space at a vertical lift transfer area.