Autonomous transport vehicle charging system

• US 9,758,049 B2
• Filed: 11/22/2016
• Issued: 09/12/2017
• Est. Priority Date: 12/15/2010
• Status: Active Grant

• Current Assignee: Symbotic, Llc
• Original Assignee: Symbotic, Llc
• Inventors: Sullivan, Robert, Vasilyev, Dmitry
• Primary Examiner(s): Fantu, Yalkew
• Application Number:
  US15/359,366
• Publication Number:
  US 20170072809A1
• Time in Patent Office: 294 Days
• Field of Search: 320109
• CPC Class Codes: B60G 5/00 Resilient suspensions for a set of tandem wheels or axles having interrelated movements
• CPC Class Codes: B60L 53/63 in response to network capacity
• CPC Class Codes: B60L 53/66 Data transfer between charging stations and vehicles
• CPC Class Codes: B60S 5/00 Servicing, maintaining, repairing, or refitting of vehicles vehicles adapted to carry a workshop for servicing or maintenance B60P3/14; servicing rail locomotives B61K
• CPC Class Codes: B65G 1/0492 with cars adapted to travel in storage aisles
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses
• CPC Class Codes: B65G 47/04 for feeding articles
• CPC Class Codes: B65G 67/02 Loading or unloading land vehicles
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: G06Q 20/105 involving programming of a portable memory device, e.g. IC cards, "electronic purses"
• CPC Class Codes: G06Q 30/0215 Including financial accounts
• CPC Class Codes: G06Q 40/00 Finance; Insurance; Tax strategies; Processing of corporate or income taxes
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles

Abstract

A charging system for autonomous transport vehicles including at least one charging contact disposed on each pick floor level of a storage and retrieval system, each of the at least one charging contact being located at a transfer station, at least one power supply configured to supply power to the at least one charging contact, and a controller in communication with the transfer station and being configured to communicate information relating to a transfer of items between the transfer station and a predetermined one of the autonomous transport vehicles and to apply power from the power supply to the at least one charging contact for charging the predetermined autonomous transport vehicle corresponding to the transfer and located at the transfer station, wherein the controller is configured to supply power to the charging contacts simultaneously with the predetermined autonomous transport vehicle exchanging items related to the transfer at the transfer station.

Claims

1. A method comprising:

providing at least one autonomous transport vehicle;

providing at least one transfer station having an allocated and unallocated state where in the allocated state the at least one transfer station allows transfer of items from and to the at least one autonomous transport vehicle;

providing at least one charging station on each pick floor level of a storage and retrieval system, each of the at least one charging station being located at a respective one of the at least one transfer station;

providing at least one power supply configured to supply power to the at least one charging station;

communicating, with a controller in communication with at least one of the at least one charging station or the at least one autonomous transport vehicle, information related to a transfer of items between a predetermined at least one transfer station and a predetermined one of the at least one autonomous transport vehicle; and

with the controller, applying power from the at least one power supply to the at least one charging station for charging the at least one autonomous transport vehicle located at the at least one transfer station, wherein the controller supplies power to the at least one charging station for charging the predetermined one of the at least one autonomous transport vehicle corresponding to the transfer of items with the predetermined one of the at least one autonomous transport vehicle transferring the items at the predetermined at least one transfer station with the predetermined at least one transfer station in the allocated state and communicating with another of the at least one autonomous transport vehicle and identifying an unallocated time period with the predetermined at least one transfer station in the unallocated state for charging the other one of the at least one autonomous transport vehicle at the at least one charging station of the predetermined at least one transfer station in the unallocated state.

2. The method of claim 1, further comprising:

providing at least one vertical lift within the storage and retrieval system;

providing at least one pick floor level having storage locations, at least one vestibule and a transfer deck connecting the storage locations with the at least one vestibule, each of the at least one vestibule having at least one of the at least one transfer station providing access to a respective one of the at least one vertical lift; and

controlling operations, with the controller, of at least one of the at least one vertical lift and operations of at least one charging station located in vestibules associated with the respective vertical lift.

3. The method of claim 2, further comprising controlling, with a level controller connected to each pick floor level, storage and retrieval operations of a respective level, and linking, with the level controller, operations of the at least one vertical lift with associated charging stations such that access to the at least one vertical lift is prevented when one or more of the associated charging stations is inoperable.

4. The method of claim 2, wherein the at least one power supply is commonly connected to charging stations of vertically adjacent ones of the at least one pick floor level.

5. The method of claim 4, wherein the charging stations are commonly connected to the at least one power supply comprising a two by two array of charging stations where a first two of the charging stations in the array are located on a first pick floor level and a second two of the charging stations in the array are located on a second pick floor level, the first two of the charging stations and the second two of the charging stations being vertically stacked one above the other.

6. The method of claim 2, further comprising providing each vestibule with at least two charging stations and arranging the at least two charging stations on a common linear path.

7. The method of claim 2, further comprising providing the transfer deck with an array of autonomous transport vehicle travel paths, the array including longitudinal travel paths providing access to the storage locations and the at least one vestibule and transverse travel paths providing shunts between the longitudinal travel paths.

8. The method of claim 2, further comprising reserving, with the controller, one or more of the at least one charging station for allowing one of the at least one autonomous transport vehicle access to the one or more of the at least one charging station.

9. The method of claim 2, further comprising re-routing, with the controller, one of the at least one autonomous transport vehicle destined for a charging station at a first vestibule to a charging station at another vestibule when the charging station at the first vestibule is inoperable.

10. The method of claim 2, wherein in the unallocated state the at least one transfer station does not allow the transfer of items from and to the at least one autonomous transport vehicle.

11. The method of claim 2, wherein the other of the at least one autonomous transport vehicle traverses from a position on a transfer deck or in a picking aisle to the predetermined at least one transfer station along at least one shunt path between the position on the transfer deck or in the picking aisle and the predetermined at least one transfer station and, wherein the other of the at least one autonomous transport vehicle enters the at least one vestibule from the at least one shunt path.

12. The method of claim 1, wherein the other of the at least one autonomous transport vehicle traverses from a position on a transfer deck or in a picking aisle to the predetermined at least one transfer station along at least one shunt path between the position on the transfer deck or in the picking aisle and the predetermined at least one transfer station.

13. The method of claim 12, wherein the other of the at least one autonomous transport vehicle is in an idle state at the position on the transfer deck or in the picking aisle.

14. A warehouse storage and retrieval system comprising

at least one autonomous transport vehicle;

at least one transfer station having an allocated and unallocated state where in the allocated state the at least one transfer station allows transfer of items from and to the at least one autonomous transport vehicle;

at least one charging station disposed on each pick floor level of the warehouse storage and retrieval system, each of the at least one charging station being located at a respective one of the at least one transfer station;

at least one power supply configured to supply power to the at least one charging station; and

a controller communication with at least one of the at least one charging station or the at least one autonomous transport vehicle, where the controller is configured to

communicate information related to a transfer of items between a predetermined at least one transfer station and a predetermined one of the at least one autonomous transport vehicle,

apply power from the at least one power supply to the at least one charging station for charging the at least one autonomous transport vehicle located at the at least one transfer station, wherein the controller supplies power to the at least one charging station for charging the predetermined one of the at least one autonomous transport vehicle corresponding to the transfer of items with the predetermined one of the at least one autonomous transport vehicle transferring the items at the predetermined at least one transfer station with the predetermined at least one transfer station in the allocated state, and

communicate with another of the at least one autonomous transport vehicle to identify an unallocated time period with the predetermined at least one transfer station in the unallocated state for charging the other of the at least one autonomous transport vehicle at the at least one charging station of the predetermined at least one transfer station in the unallocated state.

15. The warehouse storage and retrieval system of claim 14, further comprising:

at least one vertical lift within the storage and retrieval system;

at least one pick floor level having storage locations;

at least one vestibule; and

a transfer deck connecting the storage locations with the at least one vestibule, each of the at least one vestibule having at least one of the at least one transfer station configured to provide access to a respective one of the at least one vertical lift;

wherein the controller is configured to control operations of at least one of the at least one vertical lift and operations of at least one charging station located in vestibules associated with the respective vertical lift.

16. The warehouse storage and retrieval system of claim 15, further comprising a level controller connected to each pick floor level, the level controller being configured to

control storage and retrieval operations of a respective level, and

link operations of the at least one vertical lift with associated charging stations such that access to the at least one vertical lift is prevented when one or more of the associated charging stations is inoperable.

17. The warehouse storage and retrieval system of claim 15, wherein the at least one power supply is commonly connected to charging stations of vertically adjacent ones of the at least one pick floor level.

18. The warehouse storage and retrieval system of claim 17, wherein the charging stations are commonly connected to the at least one power supply comprising a two by two array of charging stations where a first two of the charging stations in the array are located on a first pick floor level and a second two of the charging stations in the array are located on a second pick floor level, the first two of the charging stations and the second two of the charging stations being vertically stacked one above the other.

19. The warehouse storage and retrieval system of claim 15, wherein each at least one vestibule includes at least two charging stations arranged on a common linear path.

20. The warehouse storage and retrieval system of claim 15, wherein the transfer deck includes an array of autonomous transport vehicle travel paths, the array including longitudinal travel paths providing access to the storage locations and the at least one vestibule and transverse travel paths providing shunts between the longitudinal travel paths.

21. The warehouse storage and retrieval system of claim 15, wherein the controller is configured to reserve one or more of the at least one charging station for allowing one of the at least one autonomous transport vehicle access to the one or more of the at least one charging station.

22. The warehouse storage and retrieval system of claim 15, wherein the controller is configured to re-route one of the at least one autonomous transport vehicle destined for a charging station at a first vestibule to a charging station at another vestibule when the charging station at the first vestibule is inoperable.

23. The warehouse storage and retrieval system of claim 15, wherein in the unallocated state the at least one transfer station does not allow transfer of items from and to the at least one autonomous transport vehicle.

24. The warehouse storage and retrieval system of claim 15, wherein the other of the at least one autonomous transport vehicle traverses from a position on a transfer deck or in a picking aisle to the predetermined at least one transfer station along at least one shunt path between the at least one autonomous vehicle position on the transfer deck or in the picking aisle and the predetermined at least one transfer station and, wherein the other of the at least one autonomous transport vehicle enters the at least one vestibule from the at least one shunt path.

25. The warehouse storage and retrieval system of claim 14, wherein the other of the at least one autonomous transport vehicle traverses from a position on a transfer deck or in a picking aisle to the predetermined at least one transfer station along at least one shunt path between the at least one autonomous vehicle position on the transfer deck or in the picking aisle and the predetermined at least one transfer station.

26. The warehouse storage and retrieval system of claim 25, wherein the other of the at least one autonomous transport vehicle is in an idle state at the position on the transfer deck or in the picking aisle.