Air cushioned materials handling system

• US 10,858,202 B1
• Filed: 06/21/2018
• Issued: 12/08/2020
• Est. Priority Date: 04/14/2014
• Status: Active Grant

• Current Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Original Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Inventors: McNamara, Alexander Michael, Mathiesen, Thomas Meilandt, Smith, Korwin Jon, Famularo, Jason Michael, Boyapati, Sridhar, Taylor, Amber Autrey, Pageau, Felix Joseph Etienne
• Primary Examiner(s): Dillon, Jr., Joseph A
• Application Number:
  US16/015,095
• Time in Patent Office: 901 Days
• Field of Search: 406 88, 406 89, 414676, 180125, 104 232, 472129, 700230
• CPC Class Codes: B65G 1/1375 the orders being assembled on a commissioning stacker-crane or truck
• CPC Class Codes: B65G 2203/041 Camera
• CPC Class Codes: B65G 2203/042 Sensors
• CPC Class Codes: B65G 53/00 Conveying materials in bulk through troughs, pipes or tubes by floating the materials or by flow of gas, liquid or foam

Abstract

Described are systems for a materials handling facility to emit air from a floor which is used to generate an air cushion upon which one or more totes may move. The floor may contain one or more apertures which receive air from an air reservoir which is supplied by an air source such as a compressor. Air emitted by these apertures is constrained by a deck of the tote, forming an air cushion upon which the tote rests. In some implementations the air cushion may be maintained while a user is within a threshold distance, and discontinued when the user is beyond the threshold distance.

Claims

1. A system comprising:

a utility floor;

a first wireless power unit at or below the utility floor, the first wireless power unit configured to transmit power;

a first aperture configured to emit air at a surface of the utility floor;

a second aperture configured to emit air at the surface of the utility floor;

a sensor to provide position data indicative of a position of a tote over a portion of the utility floor containing one or more of the first aperture or the second aperture;

an air source configured to deliver a flow of air;

a first air reservoir coupled to the air source and coupled to the first aperture, the first air reservoir configured to direct at least a portion of the flow of air received from the air source through the first aperture to the utility floor;

a second air reservoir coupled to the air source and coupled to the second aperture, the second air reservoir configured to direct at least a portion of the flow of air received from the air source through the second aperture to the utility floor;

a switching manifold configured to selectively direct at least a portion of the flow of air from the air source to one or more of the first air reservoir or the second air reservoir; and

a switching manifold controller configured to operate the switching manifold to direct a portion of air from the air source to the one or more of the first air reservoir or the second air reservoir, responsive to the position data, to provide air from apertures beneath at least a portion of the tote.

2. The system of claim 1, further comprising:

an inventory location, the inventory location comprising;

one or more shelves, racks, cases, cabinets, bins, pallets, or tubs configured to contain one or more items; and

a deck configured to be supported by at least a portion of the air emitted from the surface of the utility floor, the deck supporting an item stowage area.

3. The system of claim 1, further comprising:

the tote, the tote comprising;

a frame configured to provide an item stowage area configured to contain one or more items;

a deck coupled to the frame, the deck configured to be supported by at least a portion of the air emitted from the surface of the utility floor;

a skirt comprising a flexible material mounted to a perimeter of the deck and configured to accept and retain a portion of the air emitted from the utility floor to at least partially inflate the skirt;

a second wireless power unit proximate to the deck, the second wireless power unit configured to electromagnetically couple to the first wireless power unit to receive the power; and

one or more electronic devices configured to consume the power received by the second wireless power unit.

4. The system of claim 1, further comprising:

an imaging device configured to acquire image data; and

a computing device comprising;

a communication interface configured to couple to one or more of the tote, the imaging device, or the switching manifold;

a memory storing computer-executable instructions; and

a hardware processor in communication with the communication interface and the memory, wherein the hardware processor is configured to execute the computer-executable instructions to;

access the image data;

determine a position of the tote on the utility floor using the image data;

determine one or more air reservoirs associated with the position of the tote on the utility floor; and

operate the switching manifold to direct a flow of air to one or more apertures corresponding to the one or more air reservoirs that are associated with the position of the tote.

5. A system comprising:

a utility floor;

a first aperture configured to emit air at a surface of the utility floor;

a second aperture configured to emit air at the surface of the utility floor;

a sensor to provide position data indicative of a position of a tote over a portion of the utility floor containing one or more of the first aperture or the second aperture;

an air source configured to deliver a flow of air;

a first air reservoir coupled to the air source and coupled to the first aperture, the first air reservoir configured to direct at least a portion of the flow of air received from the air source through the first aperture to the utility floor;

a second air reservoir coupled to the air source and coupled to the second aperture, the second air reservoir configured to direct at least a portion of the flow of air received from the air source through the second aperture to the utility floor;

a switching manifold configured to selectively direct at least a portion of the flow of air from the air source to one or more of the first air reservoir or the second air reservoir; and

a switching manifold controller configured to operate the switching manifold to direct a portion of air from the air source to the one or more of the first air reservoir or the second air reservoir, responsive to the position data, to provide air from apertures beneath at least a portion of the tote.

6. The system of claim 5, further comprising:

an inventory location, the inventory location comprising;

one or more shelves, racks, cases, cabinets, bins, pallets, or tubs configured to contain one or more items; and

a deck configured to be supported by at least a portion of the air emitted from the surface of the utility floor.

7. The system of claim 5, the tote comprising:

an item stowage area configured to contain one or more items; and

a deck supporting the item stowage area, the deck configured to be supported by at least a portion of the air emitted from the surface of the utility floor.

8. The system of claim 7, the tote further comprising one or more of:

a skirt comprising a flexible material mounted to a perimeter of the deck and configured to retain a portion of the air emitted from the surface of the utility floor, or

a plurality of wheels configured to disengage the utility floor while the tote is supported by the air emitted from the surface of the utility floor.

9. The system of claim 7, the tote further comprising:

a power supply configured to provide electrical power to components in the tote, wherein the power supply comprises one or more of;

a photovoltaic cell,

a battery,

a wireless power unit receiver,

a fuel cell, or

a capacitor.

10. The system of claim 5, further comprising:

a first wireless power unit at or below the utility floor, the first wireless power unit configured to transmit power; and

wherein the tote comprises;

a second wireless power unit configured to electromagnetically couple to the first wireless power unit to receive the power; and

one or more electronic devices configured to consume the power received by the second wireless power unit.

11. The system of claim 5, wherein the sensor comprises an imaging sensor configured to acquire image data of at least a portion of a room in which the utility floor is emplaced;

the system further comprising;

an air source controller configured to operate the air source; and

a computing device comprising;

a communication interface configured to communicatively couple to the imaging sensor and the air source controller,

a memory storing computer-executable instructions, and

a hardware processor in communication with the communication interface and the memory, wherein the hardware processor is configured to execute the computer-executable instructions to;

access the image data;

use the image data to determine a user is within a threshold distance of the tote; and

use the air source controller to activate the air source to deliver the flow of air.

12. The system of claim 5, further comprising:

determining, based on a change in the position data over time, movement of the tote toward a second position on the utility floor; and

operating the switching manifold to direct a flow of air to an air reservoir coupled to apertures beneath the second position.

13. The system of claim 5, further comprising one or more environmental control devices, the one or more environmental control devices including one or more of:

an air heating unit,

an air cooling unit, or

an air cleaning unit; and

wherein the air source is configured to provide air to or receive air from the one or more environmental control devices.

14. The system of claim 5, further comprising:

a vacuum system configured to withdraw air from one or more of the first air reservoir or the second air reservoir; and

wherein the switching manifold is configured to selectively direct air between;

the one or more of the first air reservoir or the second air reservoir and the air source, or

the one or more of the first air reservoir or the second air reservoir and the vacuum system.

15. The system of claim 5, wherein the sensor comprises an imaging sensor configured to acquire image data of at least a portion of the utility floor.

16. A system comprising:

a utility floor;

a first aperture configured to emit air at a surface of the utility floor;

a second aperture configured to emit air at the surface of the utility floor;

an air source configured to deliver a flow of air;

a first air reservoir coupled to the air source and coupled to the first aperture, the first air reservoir configured to direct at least a portion of the flow of air received from the air source through the first aperture to the utility floor;

a second air reservoir coupled to the air source and coupled to the second aperture, the second air reservoir configured to direct at least a portion of the flow of air received from the air source through the second aperture to the utility floor;

a switching manifold configured to selectively direct at least a portion of the flow of air from the air source to one or more of the first air reservoir or the second air reservoir; and

a first wireless power unit at or below the utility floor, the first wireless power unit configured to transmit power.

17. The system of claim 16, further comprising:

a sensor configured to provide position data indicative of a position of a tote over a portion of the utility floor containing one or more of the first aperture or the second aperture; and

a switching manifold controller configured to operate the switching manifold to direct a portion of air from the air source to the one or more of the first air reservoir or the second air reservoir, responsive to the position data, to provide air from apertures beneath at least a portion of the tote.

18. The system of claim 16, further comprising:

a tote further comprising;

a second wireless power unit, the second wireless power unit configured to electromagnetically couple to the first wireless power unit to receive the power.

19. The system of claim 18, wherein the tote further comprises:

a frame configured to provide an item stowage area configured to contain one or more items;

a deck coupled to the frame, the deck configured to be supported by at least a portion of the air emitted from the surface of the utility floor;

a skirt comprising a flexible material mounted to a perimeter of the deck and configured to accept and retain a portion of the air emitted from the utility floor to at least partially inflate the skirt; and

one or more electronic devices configured to consume the power received by the second wireless power unit.

20. The system of claim 18, wherein the second wireless power unit receives power from the first wireless power unit when the first wireless power unit is activated to provide power.