AUTOMATED SYSTEM FOR TRANSPORTING PAYLOADS

• US 20170137222A1
• Filed: 01/31/2017
• Published: 05/18/2017
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Walmart Apollo, LLC (WalMart Inc.)
• Original Assignee: Alert Corporation
• Inventors: Lert, JR., John
• Granted Patent: US 10,435,242 B2
• Time in Patent Office: Days
• CPC Class Codes: B65G 1/0492 with cars adapted to travel in storage aisles
• CPC Class Codes: B65G 1/065 with self propelled cars
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses
• CPC Class Codes: B65G 1/1378 the orders being assembled on fixed commissioning areas remote from the storage areas

Abstract

An automated warehouse storage system including a multilevel storage array is provided. Each aisle has a set of storage levels and each level has storage locations distributed along the aisle. The guideway network extending through the multilevel storage array is configured for autonomous vehicles to move along the guideway network within the multilevel storage array. The guideway network including an inter-aisle guideway spanning at least two of the multiple aisles and a set of guideway levels extending in an aisle of the multiple aisles and disposed so that each guideway level is at a different one of the storage levels and the vehicles on the guideway level can access the storage locations distributed along the aisle. Each set of guideway levels is connected to the inter-aisle guideway forming a common guideway path so that a vehicle can move between inter-aisle guideway and each guideway level along the common guideway path.

Claims

1. An automated warehouse storage system, comprising:

a multilevel storage array with storage distributed along multiple aisles, wherein each aisle has a set of storage levels and each level has storage locations distributed along the aisle;

an inter-aisle floor that spans at least two of the multiple aisles and is configured for robotic vehicles to move along the at least one inter-aisle floor;

a guideway network extending through the multilevel storage array and configured for robotic vehicles to move along the guideway network within the multilevel storage array the guideway network comprising;

a set of guideway levels extending in at least one aisle of the multiple aisles and disposed so that each guideway level of the set of guideway levels is at a different one of the storage levels and the robotic vehicles on a respective guideway level can access the storage locations distributed along a respective aisle; and

a vertical transition guideway disposed within the at least one aisle connecting one guideway level with another different guideway level;

wherein at least one of the guideway levels is selectably connected to the vertical transition guideway and the automated warehouse storage system further comprises a controller configured to effect selection between a connected and disconnected state of the at least one of the guideway levels.

2. The automated warehouse storage system of claim 1, wherein the one guideway level belongs to the set of guideway levels and the another different guideway level belongs to another set of guideway levels.

3. The automated warehouse storage system of claim 1, wherein the vertical transition guideway communicably connects each of the set of guideway levels to the inter-aisle floor forming a common vertical transition guideway connecting the inter-aisle floor and each guideway level, enabling robotic vehicles to move between the inter-aisle floor and guideway levels that are connected to the vertical transition guideway.

4. The automated warehouse storage system of claim 1, further comprising a switch between at least one of the guideway levels and the vertical transition guideway.

5. The automated warehouse storage system of claim 1, further comprising a robotic vehicle moving on each guideway level that moves along the aisle to the storage locations.

6. The automated warehouse storage system of claim 1, wherein the robotic vehicle is self-guided and configured to operate with or without rail-guidance.

7. An automated warehouse storage system method of operation, the method comprising:

in a multilevel storage array comprising storage distributed along multiple aisles, wherein each aisle has a set of storage levels and each level has storage locations distributed along the aisle and having an inter-aisle floor that spans at least two of the multiple aisles;

one or more robotic vehicles moving along the at least one inter-aisle floor and along a guideway network extending throughout the multilevel storage array;

the one or more robotic vehicles accessing the storage locations along a respective aisle via a set of guideway levels of the guideway network extending in at least one aisle of the multiple aisles and disposed so that each guideway level of the set of guideway levels is at a different one of the storage levels;

the one or more robotic vehicles further accessing a vertical transition guideway disposed within the at least one aisle connecting one guideway level with another different guideway level, as the one or more robotic vehicles move from one level to another level of the multilevel storage array;

a controller controlling access by the one or more robotic vehicles to the guideway levels by selecting between a connected and a disconnected state of at least one of the guideway levels selectably connected to a vertical transition guideway disposed within the at least one aisle and connecting one guideway level with another different guideway level, in such a way that controls which levels are accessed by the one or more robotic vehicles as they move from one level to another level of the multilevel storage array.

8. The method of claim 7, further comprising the vertical transition guideway communicably connecting each of the set of guideway levels to the inter-aisle floor forming a common vertical transition guideway connecting the inter-aisle floor and each guideway level, enabling the one or more robotic vehicles moving between the inter-aisle floor and guideway levels that are connected to the vertical transition guideway.

9. The method of claim 7, wherein the controller controlling access comprises the controller activating a switch between at least one of the guideway levels and the vertical transition guideway.

10. The method of claim 7, wherein the one or more robotic vehicles are self-guided and operates with or without rail-guidance.

11. An automated warehouse storage system, comprising:

a multilevel storage array with storage distributed along multiple aisles, wherein each aisle has a set of storage levels and each level has storage locations distributed along the aisle; and

an inter-aisle floor that spans at least two of the multiple aisles and is configured for robotic vehicles to move along the at least one inter-aisle floor;

a guideway network extending through the multilevel storage array and configured for autonomous vehicles to move along the guideway network within the multilevel storage array, the guideway network comprising;

at least one zone of vertical space within a respective aisle;

wherein each zone of vertical space comprises;

a set of guideway levels extending in the respective aisle and disposed so that each guideway level of the set of guideway levels is at a different one of the storage levels and the vehicles on a respective guideway level can access the storage locations distributed along a respective aisle; and

a vertical transition guideway disposed within the respective aisle and interconnecting guideway level in the set of guideway levels with another different guideway level in the set of guideway levels.

12. The automated warehouse storage system of claim 11, wherein the respective aisle includes more than one zone of vertical space.

13. The automated warehouse storage system of claim 11, wherein the vertical transition guideway communicably connects each of the set of guideway levels to the inter-aisle floor forming a common vertical transition guideway connecting the inter-aisle floor and each guideway level, enabling robotic vehicles to move between the inter-aisle floor and guideway levels that are connected to the vertical transition guideway.

14. The automated warehouse storage system of claim 11, wherein at least one of the guideway levels is selectably connected to the vertical transition guideway and the automated warehouse storage system further comprises a controller configured to effect selection between a connected and disconnected state of the at least one of the guideway levels.

15. The automated warehouse storage system of claim 11, further comprising a switch between at least one of the guideway levels and the vertical transition guideway.

16. The automated warehouse storage system of claim 11, further comprising robotic vehicles moving on each guideway level that moves along the aisle to the storage locations.

17. The automated warehouse storage system of claim 11, wherein the robotic vehicles are self-guided and operates with or without rail-guidance.

18. An automated warehouse storage system, comprising:

a storage array having multiple levels, the storage array comprising;

storage distributed along multiple aisles, wherein each aisle has a set of storage levels and each level has storage locations distributed along the aisle;

at least one inter-aisle floor that spans at least two of the multiple aisles and is configured for robotic vehicles to move along the at least one inter-aisle floor; and

at least one zone of vertical space comprising a vertical transition interconnecting levels of the multiple levels of the storage array;

at least one robotic vehicle comprising a propulsion subsystem with at least one electric motor, transmission mechanisms, and drive wheels, enabling horizontal travel along the at least one inter-aisle floor and vertical travel from level to level of the multiple levels via the vertical transition;

a central control system (CCS) managing operation of the automated warehouse storage system;

wherein the CCS controls movement of the at least one robotic vehicle by assigning the at least one robotic vehicle to move totes to and from locations within the storage array, including assigning the at least one robotic vehicle to travel vertically between the multiple levels and horizontally across the at least one inter-aisle floor of the multiple aisles of the storage array.

19. The automated warehouse storage system of claim 18, wherein the at least one robotic vehicle moves along the at least one inter-aisle floor without requiring rail-guidance.

20. The automated warehouse storage system of claim 18, wherein the CCS controls a traffic-control function to prevent collisions between each of the at least one self-guided robot.

21. The automated warehouse storage system of claim 18, wherein the vertical transition of the at least one vertical zone comprises a ramp.

22. The automated warehouse storage system of claim 18, wherein the vertical transition of the at least one vertical zone comprises a ramp, the at least one robotic vehicle comprises gear devices disposed on drive axles, and the gear devices engage with complementary resistance features built into the ramp.

23. The automated warehouse storage system of claim 18, wherein the vertical transition of the at least one vertical zone comprises a ramp at a steep angle of incline set to reduce loss of space for storage.

24. The automated warehouse storage system of claim 18, further comprising a switch between the at least one of the multiple levels and the vertical transition of the at least one zone of vertical space.

25. The automated warehouse storage system of claim 18, wherein the respective aisle comprises two or more of the at least one zone of vertical space.

26. The automated warehouse storage system of claim 18, wherein the vertical transition communicably connects each level of the multiple levels to the at least one inter-aisle floor forming a common vertical transition connecting the at least one inter-aisle floor and each level so that when the robotic vehicle moves between the at least one inter-aisle floor and each level the robotic vehicle moves along the common vertical transition.

27. The automated warehouse storage system of claim 18, further comprising at least one picking station.

28. The automated warehouse storage system of claim 27, wherein the at least one robotic vehicle moves to and from the at least one picking station delivering and retrieving totes to and from the at least one picking station.

29. The automated warehouse storage system of claim 18, wherein the at least one robotic vehicle is self-guided, travels bi-directionally, and turns.

30. The automated warehouse storage system of claim 29, wherein the at least one robotic vehicle operates with or without rail-guidance.

31. A method of automated warehouse storage system operation, the method comprising:

in the automated warehouse storage system, the system comprising;

a storage array having multiple levels, the storage array comprising;

storage distributed along multiple aisles, wherein each aisle has a set of storage levels and each level has storage locations distributed along the aisle;

at least one inter-aisle floor that spans at least two of the multiple aisles and is configured for robotic vehicles to move along the at least one inter-aisle floor; and

at least one zone of vertical space comprising a vertical transition disposed within the respective aisle and interconnecting levels of the multiple levels of the storage array;

at least one robotic vehicle comprising a propulsion subsystem with at least one electric motor, transmission mechanisms, and drive wheels, the at least one robotic vehicle traveling horizontally along the at least one inter-aisle floor and vertically from level to level of the multiple levels via the vertical transition;

a central control system (CCS) managing operation of the automated warehouse storage system;

the CCS controlling movement of at least one robotic vehicle by assigning the at least one robotic vehicle to move totes to and from locations within the storage array, including assigning the at least one robotic vehicle to travel vertically between the multiple levels and horizontally across the at least one inter-aisle floor of the multiple aisles of the storage array; and

the at least one robotic vehicle moving totes to and from locations within the storage array by traveling vertically between the multiple levels and by traveling horizontally across the at least one inter-aisle floor of the multiple aisles of the storage array.

32. The method of claim 31, further comprising the at least one robotic vehicle moving along the at least one inter-aisle floor without requiring rail-guidance.

33. The method of claim 31, further comprising the CCS controlling a traffic-control function and preventing collisions between each of the at least one self-guided robot.

34. The method of claim 31, wherein the vertical transition of the at least one vertical zone comprises a ramp.

35. The method of claim 34, wherein the at least one robotic vehicle comprises gear devices disposed on drive axles, the gear devices engaging with complementary resistance features built into the ramp.

36. The method of claim 31, further comprising the CCS controlling access to the multiple levels by switching a switch between the at least one of the multiple levels and the vertical transition of the at least one zone of vertical space.

37. The method of claim 31, further comprising the vertical transition communicably connecting each level of the multiple levels to the at least one inter-aisle floor forming a common vertical transition connecting the at least one inter-aisle floor and each level enabling the at least one robotic vehicle moving between the at least one inter-aisle floor and each level, the at least one robotic vehicle moving along the common vertical transition.

38. The method of claim 31, further comprising at least one picking station.

39. The method of claim 38, further comprising the at least one robotic vehicle moving to and from the at least one picking station delivering and retrieving totes to and from the at least one picking station.

40. The method of claim 31, wherein the at least one robotic vehicle is self-guided, travels bi-directionally, and turns.

41. The method of claim 40, further comprising the at least one robotic vehicle operating with or without rail-guidance.

42. A method of automated warehouse storage system operation, the method comprising:

in the automated warehouse storage system;

a central control system (CCS) directing at least one robotic vehicle to move totes to and from locations within a storage array in the automated warehouse storage system by assigning the at least one robotic vehicle to travel vertically between multiple levels and horizontally across at least one inter-aisle floor of multiple aisles of the storage array to designated locations; and

the at least one robotic vehicle moving totes to and from locations within the storage array by traveling vertically between the multiple levels and by traveling horizontally across the at least one inter-aisle floor of the multiple aisles of the storage array to move totes to and from the locations within the storage array;

wherein the at least one robotic vehicle is travels bi-directionally, and turns, enabling the at least one robotic vehicle to travel along the at least one inter-aisle floor and vertically from level to level of the multiple levels via the vertical transition.

43. The method of claim 42, further comprising the at least one robotic vehicle moving along the at least one inter-aisle floor without requiring rail-guidance.

44. The method of claim 42, further comprising the CCS controlling a traffic-control function and preventing collisions between each of the at least one self-guided robot.

45. The method of claim 42, wherein the vertical transition of the at least one vertical zone comprises a ramp.

46. The method of claim 45, wherein the at least one robotic vehicle comprises gear devices disposed on drive axles, the gear devices engaging with complementary resistance features built into the ramp.

47. The method of claim 42, further comprising the CCS controlling access to the multiple levels by switching a switch between the at least one of the multiple levels and the vertical transition of the at least one zone of vertical space.

48. The method of claim 42, further comprising the vertical transition communicably connecting each level of the multiple levels to the at least one inter-aisle floor forming a common vertical transition connecting the at least one inter-aisle floor and each level enabling the at least one robotic vehicle moving between the at least one inter-aisle floor and each level, the at least one robotic vehicle moving along the common vertical transition.

49. The method of claim 42, further comprising at least one picking station.

50. The method of claim 49, further comprising the at least one robotic vehicle moving to and from the at least one picking station delivering and retrieving totes to and from the at least one picking station.

51. The method of claim 42, wherein the at least one robotic vehicle is self-guided, travels bi-directionally, and turns.

52. The method of claim 51, further comprising the at least one robotic vehicle operating with or without rail-guidance.