Systems and methods using mobile robot stations

Abstract

There are provided systems and methods that may involve using mobile robot stations at a facility. In one form, the system may include a pathway or a deck facilitating movement of mobile robots along the pathway or deck, and a mobile robot station proximate an edge of the pathway or deck. The mobile robot station may include a gate at an entrance of the mobile robot station and accessible to a mobile robot moving along the pathway or deck with the gate movable between a first position and a second position. The mobile robot can move into or out of the mobile robot station via the entrance when the gate is in the first position, and the mobile robot is blocked from moving into or out of the mobile robot station via the entrance when the gate is in the second position.

Description

SYSTEMS AND METHODS USING MOBILE ROBOT STATIONSCross-Reference to Related Application(s)

[0001] This application claims the benefit of and priority to U.S. Application No. 63 / 626,931, filed January 30, 2024, which is incorporated herein by reference in its entirety.Technical Field

[0002] This invention relates generally to mobile robot stations, and more particularly, to stations allowing the introduction and / or removal of mobile robots at a facility.Background

[0003] Automated storage and retrieval systems (ASRS) are being used increasingly in the context of fulfilling merchandise orders. In some forms, these systems may include mobile robots that move about a storage structure at an order fulfillment facility to pick and transfer containers and items. In some forms, mobile robots may travel along various pathways in the facility.

[0004] Sometimes, during movement about the facility, mobile robots may need to be updated, repaired, or receive maintenance. In these circumstances, there may be a need to remove these mobile robots from the system. In one aspect, it would be desirable to introduce multiple robot stations that can temporarily or permanently affix to, or adjoin, a structure of the facility and that may isolate the mobile robots so as to provide safety for a responding technician.Brief Description of the Drawings

[0005] Disclosed herein are embodiments of systems, apparatuses and methods involving mobile robot stations, such as may be used at automated storage and retrieval systems. This description includes drawings, wherein:

[0006] FIG. 1A is a partial perspective view of an automated storage and retrieval system in accordance with some embodiments;

[0007] FIG. IB is a partial perspective view of the automated storage and retrieval system of FIG. 1A in accordance with some embodiments;

[0008] FIG. 2 is a schematic view of a mobile robot receiving system in accordance with some embodiments;

[0009] FIGS. 3, 4, 5, 6, and 7 are perspective views of a mobile robot station in accordance with some embodiments;

[0010] FIGS. 8, 9, 10, 11, 12, 13, 14, 15, and 16 are partial perspective views of the mobile robot station of FIG. 3 that has been modified to include additional optional features in accordance with some embodiments;

[0011] FIGS. 17 and 18 are perspective views of a mobile robot station in accordance with some embodiments;

[0012] FIGS. 19, 20, 21, and 22 are side views of a mobile robot station in accordance with some embodiments;

[0013] FIGS. 23 and 24 are perspective views of a mobile robot receiving system in accordance with some embodiments;

[0014] FIG. 25 is a top view of the mobile robot receiving system of FIG. 23 in accordance with some embodiments;

[0015] FIG. 26 is a perspective view of the mobile robot receiving system of FIG. 23 in accordance with some embodiments;

[0016] FIG. 27 is a side view of the mobile robot receiving system of FIG. 23 in accordance with some embodiments;

[0017] FIG. 28 is a perspective view of a mobile robot receiving system in accordance with some embodiments;

[0018] FIG. 29 is a top view of the mobile robot receiving system of FIG. 28 in accordance with some embodiments;

[0019] FIG. 30 is a perspective view of the mobile robot receiving system of FIG. 28 in accordance with some embodiments;

[0020] FIG. 31 is a front view of the mobile robot receiving system of FIG. 28 in accordance with some embodiments;

[0021] FIG. 32 is a side view of the mobile robot receiving system in accordance with some embodiments;

[0022] FIG. 33 is a perspective view of a mobile robot receiving system in accordance with some embodiments;

[0023] FIG. 34 is a schematic view of the mobile robot receiving system of FIG. 33 in accordance with some embodiments;

[0024] FIGS. 35, 36, 37, and 38 are top views of the mobile robot receiving system of FIG. 33 in accordance with some embodiments;

[0025] FIG. 39 is a perspective of a mobile robot receiving system in accordance with some embodiments;

[0026] FIGS. 40, 41, 42, 43, 44, 45, 46, and 47 are top views of the mobile robot receiving system of FIG. 39 in accordance with some embodiments;

[0027] FIG. 48 is a perspective view of a mobile robot receiving system in accordance with some embodiments;

[0028] FIGS. 49, 50, 51, 52, and 53 are top views of the mobile robot receiving system of FIG. 48 in accordance with some embodiments;

[0029] FIGS. 54, 55, 56, and 57 are perspective views of a mobile robot receiving system in accordance with some embodiments;

[0030] FIG. 58 is a flow diagram of a process for using a mobile robot station in accordance with some embodiments;

[0031] FIG. 59 is a flow diagram of a process for using a mobile robot station in accordance with some embodiments;

[0032] FIGS. 60, 61, 62, 63, and 64 are perspective views of a mobile robot station in accordance with some embodiments;

[0033] FIGS. 65, 66, and 67 are perspective views of a mobile robot receiving system using the mobile robot station of FIG. 60 in accordance with some embodiments;

[0034] FIG. 68 is a top view of the mobile robot station of FIG. 60 located about a facility in accordance with some embodiments;

[0035] FIG. 69 is a perspective view of the mobile robot station of FIG. 60 located about a facility in accordance with some embodiments; and

[0036] FIG. 70 is a flow diagram showing a process for using a mobile robot station to receive a mobile robot in accordance with some embodiments.

[0037] Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and / or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well- understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and / or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.Detailed Description

[0038] The following description is not to be taken in a limiting sense but is made merely for the purpose of describing the general principles of exemplary embodiments. Reference throughout this specification to “one form,” “one embodiment,” “an embodiment,” “some embodiments”, “an implementation”, “some implementations”, “some applications”, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” “in some embodiments”, “in some implementations”, and similar language throughout this specification do not all refer to the same embodiment.

[0039] The terms “top” and “bottom,” “upper” and “lower” and “vertical” and “horizontal as may be used herein are by way of example and illustrative purposes only and are not meant to limit the description of the embodiments inasmuch as the referenced item can be exchanged in position and orientation. Also, as used herein, the terms "substantially" and / or "about" mean that the specified dimension or parameter may be varied within an acceptable manufacturing tolerance for a given application.

[0040] Generally speaking, pursuant to various embodiments, systems, apparatuses and methods are provided herein using mobile robot stations. In one form, the system includes: a pathway or a deck configured to facilitate movement of mobile robots along the pathway or deck. It further includes: a mobile robot station proximate an edge of the pathway or deck, the mobile robot station including: a first gate at an entrance of the mobile robot station and accessible to a mobile robot moving along the pathway or deck, the first gate movable between a first position and a second position, wherein the mobile robot can move into or out of the mobile robot station via the entrance when in the first position, wherein the mobile robot is blocked from moving into or out of the mobile robot station via the entrance when in the second position.

[0041] In some implementations, the mobile robot station includes: a second gate at an exit of the mobile robot station, the second gate movable between a third position and a fourth position, wherein the mobile robot can be moved into or out of the mobile robot station via the exit when in the third position, and wherein the mobile robot cannot be moved into or out of the mobile robot station via the exit when in the fourth position. In some implementations, the first gate and the second gate are configured such that: the first gate is blocked from moving to the first position when the second gate is in the third position; and the second gate is blocked from moving to the third position when the first gate is in the first position. In some implementations, the mobile robot station further includes a bar; the first gate includes a first plate configured to move vertically between an upward position and a downward position; the second gate includes a second plate configured to move vertically between an upward position and a downward position; and the bar is configured to move horizontally between a first setting and a second setting, the bar blocking vertical movement of the first plate in the first setting and blocking vertical movement of the second plate in the second setting. In some implementations, the mobile robot station further incudes a rotary cover lid, the rotary cover lid comprising a first portion that is rotatable to open and close the first gate and a second portion that is rotatable to open and close the second gate. In some implementations, the mobile robot station further includes: a locomotion system configured to facilitate interfacing of the mobile robot station with the edge of the pathway or deck to position the mobile robot station in a docking position; a first blocking portion and a second blocking portion, the first and second blocking portions configured to extend over the pathway or deck when the mobile robot station is in the docking position; and a rail ramp configured to allow movementof a mobile robot along a base of the mobile robot station. In some implementations, the system further includes a maintenance cart disposed adjacent the second gate of the mobile robot station, the maintenance cart disposed to facilitate transfer of the mobile robot from the mobile robot station to the maintenance cart. In some implementations, the system further includes a control circuit operatively coupled to the first gate and the second gate, the control circuit configured to limit movement of the first gate when the second gate is in the third position and to limit movement of the second gate when the first gate is in the first position. In some implementations, in the system, when the first gate is in the second position, user access to a volume of the mobile robot station is provided such that a user can insert and remove items to and from a container carried by the mobile robot within the mobile robot station. In some implementations, in the system, when the first gate is in the first position, user access to the volume of the mobile robot station is blocked such that the user cannot insert and remove items to and from the container carried by the mobile robot within the mobile robot station. In some implementations, the first gate includes a first cover portion configured to selectively allow and block access to a container carried by a mobile robot when the mobile robot is in the mobile robot station; and the second gate includes a second cover portion configured to selectively reveal and block the exit of the mobile robot station. In some implementations, the mobile robot station is configured to occupy one of three states: a first state in which the mobile robot can move through the entrance into the mobile robot station; a second state in which the first cover portion to the mobile robot station has been pivoted about an axis to block the entrance and to confine the mobile robot within the mobile robot station; and a third state in which the second cover portion has been pivoted about the axis allowing user access to remove the mobile robot from the mobile robot station. In some implementations, the system further includes: a bot blocker disposed in cooperation with a pathway, mobile robots moving along the rail structure, the bot blocker movable between a blocking position, limiting movement of a mobile robot into or out of the mobile robot station, and a non-blocking position; and a roller on the first gate, the roller moving the bot blocker from the blocking position to the non-blocking position when the first gate moves from the second position to the first position. In some implementations, the system further includes: a bot blocker disposed in cooperation with a pathway, mobile robots moving along the rail structure, the block blocker movable between a blocking position, limiting movement of a mobile robot into or out of the mobile robot station, and a non-blocking position;and a support surface for a mobile robot comprising a projecting portion, the projecting portion configured for mounting to the mobile robot station and causing the bot blocker to move from a blocking position to a non-blocking position when mounting. In some implementations, the system further includes: an access port in the mobile robot station; and an access port cover movable between an open position, in which the access port is uncovered, and a closed position, in which the access port is covered, the first gate movable to the first position only when the access port cover is in the closed position.

[0042] In another form, there is provided a method of receiving a mobile robot including: moving a mobile robot along a pathway or a deck toward a mobile robot station proximate an edge of the pathway or deck; and moving and receiving the mobile robot through a first gate at an entrance of the mobile robot station and accessible to the mobile robot moving along the pathway or deck, the first gate movable between a first position and a second position, wherein the mobile robot can move into or out of the mobile robot station via the entrance when in the first position, wherein the mobile robot is blocked from moving into or out of the mobile robot station via the entrance when in the second position.

[0043] In some implementations, the method further includes: moving the mobile robot through a second gate at an exit of the mobile robot station, the second gate movable between a third position and a fourth position, wherein the mobile robot can be moved into or out of the mobile robot station via the exit when in the third position, and wherein the mobile robot cannot be moved into or out of the mobile robot station via the exit when in the fourth position. In some implementations, the method further includes: blocking the first gate from moving to the first position when the second gate is in the third position; and blocking the second gate from moving to the third position when the first gate is in the first position. In some implementations, the method further includes: when the first gate is in the second position, providing user access to a volume of the mobile robot station such that a user can insert and remove items to and from a container carried by the mobile robot within the mobile robot station. In some implementations, the method further includes: when the first gate is in the first position, blocking user access to the volume of the mobile robot station such that a user cannot insert and remove items to and from the container carried by the mobile robot within the mobile robot station. In some implementations, the method further includes: deactivating power to the mobile robot after the mobile robot has been receivedin the mobile robot station. In some implementations, the method further includes: docking a maintenance cart to the mobile robot station adjacent the second gate; and moving the deactivated mobile robot through the second gate in the third position onto the maintenance cart.

[0044] In another form, there is provided a method of receiving a mobile robot including: transporting a deactivated mobile robot toward a mobile robot station disposed proximate an edge of a pathway or a deck; moving the mobile robot through an open external gate of the mobile robot station and onto a base of the mobile robot station, the external gate being movable between an open position and a closed position; closing the external gate and activating power to the mobile robot; and opening an internal gate of the mobile robot station, the internal gate being movable between an open position and a closed position, the internal gate providing the mobile robot with access to the pathway or deck to allow the mobile robot to move along the pathway or deck; wherein one of the external and internal gates is blocked from moving to an open position when the other of the external and internal gates is in an open position.

[0045] In one aspect, and without limitation, this disclosure is directed generally to a facility, such as an order fulfdlment facility, that includes multiple mobile robots (or bots) that operate to pick and transfer containers in the context of an automated storage and retrieval system. In one form, mobile robots move about the facility and retrieve containers, or totes, of goods that are stored in specific storage locations in the facility, as part of the automated storage and retrieval system. In some situations, a specific mobile robot may need to be updated or repaired. These or other similar situations may require removal of the bot from the system, possibly followed by introduction of a new mobile robot.

[0046] Currently, any scenario requiring removal or induction (or introduction) of the bots may require an emergency stop (e-stop) of part or all of the system, i.e., complete stoppage of all or part of the system. In one aspect, and without limitation, it may be desirable to minimize the number of partial or complete system stops that are required in case of an anomaly involving a mobile robot. Some scenarios of mishaps may require an individual, such as a technician, to physically enter a portion of the system to address the mobile robot. In this instance, the system and / or facility may be shut down partially or completely to ensure the safety of the individual.

[0047] In one aspect, and without limitation, the present disclosure relates to multiple robot station concepts that can temporarily or permanently affix to, or adjoin, a structure of the facility,such as from the side of an aisle or from the side of a deck. The mobile robot stations generally isolate the mobile robot so as to provide safety for a responding technician. In one form, the mobile robot may need to have some charge so that it can travel to the station and may need to communicate so that the station can be prepared for arrival of the mobile robot. Otherwise, a portion of the system may have to be shut down for mobile robots to be removed or introduced. It is desirable to eliminate this system down time.

[0048] In another aspect, and without limitation, the present disclosure involves a mobile robot station system with additional capabilities that allows it to operate as a more universal workstation. This mobile robot station system allows a user to interact safely with a mobile robot in multiple ways. More specifically, it is contemplated that the system may safely allow a user to do one or more of the following: (1) gain access to the products carried by the mobile robot or deposit products with the mobile robot; (2) gain access to the mobile robot to induct a tote or remove a tote from the mobile robot; and (3) gain access to the mobile robot to induct or remove the mobile robot itself from a certain operational portion of the facility (or work area). In one form, the mobile robot station may act as a parking lot for a mobile robot outside of the traffic flow of other mobile robots and may also allow the mobile robot to recharge itself at the station.

[0049] FIG. 1A shows a partial view of an embodiment of an order fulfillment facility 100 showing a storage structure 102, including a number of bays 104 of storage locations 106. In particular, each bay 104 includes a y-z array of storage locations 106 in horizontal rows and level changing towers, or vertical towers, along the rows. As explained below, mobile robots 150 may travel between storage levels in the z-direction within the level changing towers. Pairs of bays 104 may be arranged to face each other, separated by pathways 108. In one form, it is contemplated that the pathways may be aisles 108. An aisle 108 may have a width such that a mobile robot 150 traveling within an aisle 108 may transfer totes to the bays 104 on either side of the aisle 108. As explained hereinafter, the aisles 108 may be wide enough for a human to enter into an aisle 108 between bays 104 to make repairs or otherwise service components within an aisle 108.

[0050] The order fulfillment facility 100 may further include decks 112 (or transit planes or areas) spaced apart at different horizontal levels of the storage structure 102. The decks 112 may extend between the aisles 108 so that robots 150 can maneuver in the x-y plane of each deck 112 to travel between different aisles 108. In some embodiments, the decks 112 may be verticallyspaced apart from each other, so that a technician can reach all areas within an aisle 108 serviced by a particular deck 112. The spacing between decks 112 may be different in various embodiments. In addition to providing access to the aisles 108, each pair of decks 112 allows transfers by mobile robots 150 to / from a workstation 110. In some forms, mobile robots 150 may come to a workstation 110 from a first deck 112-1, and mobile robots 150 may exit a workstation 110 from a second deck 112-2. Alternatively, in some forms, mobile robots 150 may come to a workstation 110 from deck 112-2 and exit from first deck 112-1.

[0051] FIG. IB shows examples of workstations 110. In some embodiments, each workstation 110 is equipped to receive a pair of mobile robots 150. A first mobile robot 150 at a workstation 110 may carry product containers (or totes) with items for fulfilling product requests. A second mobile robot 150 at the workstation 110 may carry order containers (or totes) within which items from the product totes are placed to fulfill product requests. Workers at a workstation 110 manually transfer items from a product tote to an order tote under guidance of an inventory control system at the workstation 110.

[0052] The mobile robots 150 for both the product and order totes arrive from one of the decks, for example deck 112-1. Once items are transferred from the product totes to the order totes, the mobile robots 150 may depart the workstation 110, for example via deck 112-2. Mobile robots 150 carrying product and order totes continuously cycle through the workstations 110. In FIG. 1A, each workstation 110 is serviced by a single deck 112, which serves as the entry to, and exit from, the workstation 110. Further details relating to the structure and operation of embodiments of the workstations are disclosed in U.S. Patent No. 10,040,632 and U.S. Patent No. 11,142,398, which patents are incorporated by reference herein in their entirety. In some forms, as described further below, it may be desirable to attach or position a mobile robot station on or adjacent to an aisle 108 or deck 112 that can receive a mobile robot 150 needing servicing.

[0053] As noted above, the order fulfillment facility 100 may further include a number of mobile robots 150 for transferring totes or other product containers to and from workstations 110 and storage locations 106 in the bays 104. In certain embodiments, mobile robots 150 may be self- guided so as to move horizontally within aisles 108 to transfer totes or other product containers between the mobile robots 150 and storage locations 106. For example, a track system including horizontal rails may be affixed to bays 104 within an aisle 108 at different vertical levels. Thehorizontal rails provide access to storage shelves on either side of an aisle 108 in the x-direction on a given level. As noted above, the bays 104 may include level changing towers within which the mobile robots 150 may travel vertically in the z-direction between levels of storage locations 106.

[0054] In another form, the track system may be in the form of guidelines, such as magnetic guidelines, which may include navigational aids, such as RFID tags. The track system may therefore include horizontal rails, guidelines, and / or some combination thereof. In one example, horizontal rails may be used in the aisles 108, while guidelines may be embedded in panels forming at least some of the decks 112. The decks 112 allow inter-aisle travel of mobile robots 150 at different levels of the storage structure 102. Further details of storage structures, track systems, and mobile robots 150 that may be used in conjunction with the present technology are described for example in the following U.S. patents: U.S. Patent No. 9,139,363; U.S. PatentNo. 10,435,241; and previously mentioned U.S. Patent No. 11,142,398, which patents are each incorporated by reference herein in their entirety.

[0055] Accordingly, in some forms, there is disclosed a facility 100 with pathways 108 and decks 112, and with mobile robots 150 configured to move along the pathways 108 and decks 112 at the facility 100. The facility 100 may be in the form of an order fulfillment facility that includes storage locations 106 for storing containers containing goods / items, with each storage location 106 being accessible by a pathway 108. Further, mobile robots 150 are configured to access the storage locations 106 to deposit or retrieve containers at the storage locations 106.

[0056] The order fulfilment facility 100 described above is one example of a facility 100 where mobile robots 150 move about the facility 100 engaged in certain tasks. During the course of this movement, mobile robots 150 may encounter circumstances that cause them to be damaged, impair certain functioning, or otherwise require repair. These circumstances may be internal (such as an internal component failure) or external (such as running into an obstacle). In these instances, it is desirable to localize the problem by having the mobile robot travel to a station so that the entire facility (or a large part of it) does not have to be shut down. Approaches described in this disclosure may generally involve the use of mobile robot stations in the facility 100 to create an isolation zone, or sort of airlock, about a damaged or dysfunctional mobile robot 150 until it can be deactivated and removed to a secure area.

[0057] FIG. 2 shows a schematic example of a mobile robot receiving system 200. It is generally contemplated that this system 200 involves a mobile robot station that can be used to isolate and remove a mobile robot that may be damaged or require some sort of maintenance. It is also contemplated that this system 200 may be used to introduce a new mobile robot, such as, for example, introducing a functional mobile robot as a substitute or replacement for a dysfunctional one. This new mobile robot may then, for example, perform order fulfillment tasks that the replaced mobile robot was performing.

[0058] In one form, as shown in FIG. 2, the mobile receiving system 200 includes a pathway 202 or a deck 204 that is configured to facilitate movement of mobile robots 206 along the pathway 202 or deck 204. For example, the pathway 202 or deck 204 may include some form of navigational system to guide movement of the mobile robots 206, such as, without limitation, a rail / track system, painted or magnetic guidelines, RFID tags, fiducial markers, etc. Further, as can be seen, in one form, it is contemplated that the pathways 202, decks 204, and mobile robots 206 may all be included in a facility 208, such as, for instance, an order fulfillment facility with storage locations 210 for storing various types of items / goods.

[0059] The mobile robot receiving system 200 also includes a mobile robot station 212 disposed at, bordering, or proximate an edge of a pathway 202 or deck 204. In one form, the mobile robot station 212 may include a base 214 for supporting a mobile robot, a first gate 216 that is accessible to a mobile robot 206 moving along the pathway 202 or deck 204 with the first gate 216 being movable between a first position and a second position, and a second gate 218 that is movable between a third position and a fourth position. In one form, the first and third positions are open positions, and the second and fourth positions are closed positions. In addition, in this form, the first gate 216 may be at an entrance of the mobile robot station 212 and accessible to a mobile robot 206 moving along the pathway 202 or deck 204. In other words, the first gate 216 may be movable between a first position and a second position, in which the mobile robot 206 can move into or out of the mobile robot station 212 via the entrance when in the first position, and in which the mobile robot 206 is blocked from moving into or out of the mobile robot station 212 via the entrance when in the second position.

[0060] Further, in one form, the mobile robot station 212 may include a second gate 218. The second gate 218 may be at an exit of the mobile robot station 212. In other words, the secondgate 218 may be movable between a third position and a fourth position, in which the mobile robot 206 can be moved into or out of the mobile robot station 212 via the exit when in the third position, and in which the mobile robot 206 cannot be moved into or out of the mobile robot station 212 via the exit when in the fourth position.

[0061] In some forms, for safety purposes, the first gate 216 and the second 218 gate may be configured such that the second gate 218 is blocked from moving to an open position when the first gate 216 is in an open position. In other words, the first gate 216 is blocked from moving to the first position when the second gate 218 is in the third position, and the second gate 218 is blocked from moving to the third position when the first gate 216 is in the first position. Thus, the gates 216, 218 may be interlinked and would not be open at the same time. The gates 216, 218 of the mobile robot station 212 can be considered to be forming a sort of crude airlock for receiving a mobile robot 206.

[0062] In one form, it is contemplated that the mobile robot station 212 may include a charging rail or portion, or charger 219, that is connected to the power infrastructure of the facility 208. A mobile robot 206 entering and occupying the mobile robot station 212 may utilize this charger 219 to recharge its power supply. As one example, a mobile robot 206 may include pinion(s) that it can extend to engage the charger 219 to recharge and may then retract the pinion(s) when finished recharging.

[0063] In addition, optionally, the system 200 may include a maintenance (or transport) cart 220 disposed adjacent the second gate 218. The maintenance cart 220 is next to the second gate 218 so as to facilitate transfer of a mobile robot 206 from the mobile robot station 212 to the maintenance cart 220. The maintenance cart may then transport the mobile robot 206 to a maintenance area, such as, for example, to repair or perform maintenance on the mobile robot 206.

[0064] In one form, it is contemplated that the mobile robot receiving system 200 may include a sensor 222 configured to detect a presence of a mobile robot 206 in the mobile robot station 212. Any of various types of sensors may be used, including, for example, weight sensors, proximity sensors, pressure sensors, motion detectors / sensors, position sensors, etc. Depending on the type of sensor 222, it may be located at the mobile robot station 212 or it may be disposed at a remote location. These sensors 222 may be coupled to, or coordinated with, the first andsecond gates 216, 218 so as to trigger their opening and closing by detection of the mobile robot 206.

[0065] In one form, it is contemplated that the system 200 may include a control circuit 224 that is operatively coupled to the first gate 216 and the second gate 218. The control circuit 224 may be configured to limit movement of one of the first and second gates 216, 218 when the other of the first and second gates 216, 218 is in an open position. In other words, the control circuit 224 may be operatively coupled to the first gate 216 and the second gate 218, and it may be configured to limit movement of the first gate 216 when the second gate 218 is in the third position and to limit movement of the second gate 218 when the first gate 216 is in the first position. The control circuit 224 may be coupled to the sensor 222 such that, when the sensor detects the mobile robot 206 at a certain position, this detection may trigger opening of one of the first and second gates 216, 218 or closing of one or both of the first and second gates 216 / 218. The control circuit 224 may be located, entirely or in part, at the mobile robot station 212 or at a remote location.

[0066] In this context, the term control circuit 224 refers broadly to any microcontroller, computer, or processor-based device with processor, memory, and programmable input / output peripherals, which is generally designed to govern the operation of other components and devices. It is further understood to include common accompanying accessory devices, including memory, transceivers for communication with other components and devices, etc. These architectural options are well known and understood in the art and require no further description here. The control circuit 224 may be configured (for example, by using corresponding programming stored in a memory as will be well understood by those skilled in the art) to carry out one or more of the steps, actions, and / or functions described herein.

[0067] As stated, the control circuit 224 may include, or be coupled to, common accompanying accessories, such as, for example, a memory, a network interface, and wireless network(s). The memory can, for example, store non-transitorily computer instructions that cause the control circuit 224 to operate as described herein, when the instructions are executed, as is well known in the art. Further, the network interface may enable the control circuit 224 to communicate with other elements (both internal and external to the system). This network interface is well understood in the art. The network interface can communicatively couple the control circuit 224to the wireless network and whatever other networks may be appropriate for the circumstances. While one control circuit 224 is shown, in some forms, the functionalities of the control circuit 224 may be implemented on a plurality of processor devices communicating on a network.

[0068] FIGS. 3-7 show an example of a mobile robot station 300 with a mobile robot 301 disposed therein. FIG. 3 shows the mobile robot station 300 with the first gate 302 in a closed position and with the second gate 304 in an open position. The mobile robot station 300 includes a sliding bar 306 that is shown in a position in which the second gate 304 has been allowed to move downward to an open position. Simultaneously, the position of the sliding bar 306 keeps the first gate 302 in a raised, closed position and blocks downward movement of the first gate 302 to an open position. Thus, this form uses a mechanical mechanism to prevent both gates 302, 304 being open at the same time, rather than a control circuit / sensors approach.

[0069] As can be seen, in this particular form, the mobile robot station 300 includes a sliding bar 306, the first gate 302 generally includes a first sliding plate 320 configured to move vertically between an upward position and a downward position, the second gate 304 generally includes a second sliding plate 322 configured to move vertically between an upward position and a downward position. In this form, the sliding bar 306 slides horizontally between a first setting and a second setting with the sliding bar 306 blocking vertical movement of the first sliding plate 320 in the first setting and blocking vertical movement of the second sliding plate 322 in the second setting. In FIG. 3, the sliding bar 306 is in the first setting.

[0070] FIG. 3 also shows a maintenance cart 310 next to the open second gate 304 of the mobile robot station 300. In one form, the maintenance cart 310 includes some form of locomotion, such as wheels 312, to allow the maintenance cart 310 to be positioned next to the second gate 304 and to allow the maintenance cart 310 to transport the mobile robot 301 to a maintenance area. In one form, it is contemplated that the height of the maintenance cart 310 may be adjusted (such as via a jack) so that its support surface 314 is level with the base of the mobile robot station 300. Further, in some forms, it is contemplated that alignment features (such as pins) may be used to temporarily connect and align the mobile robot station 300 with the maintenance cart 310 to allow a mobile robot 301 to be moved from the station 300 to the cart 310.

[0071] In some forms, it is contemplated that power to the mobile robot 301 has been deactivated when the mobile robot 301 has moved into the mobile robot station 300. In someforms, it is contemplated that the mobile robot station 300 may be open from the top to allow a technician to manually deactivate the mobile robot 301 after it has arrived, possibly when both gates are in closed positions. Following deactivation, the mobile robot 301 may be moved to the maintenance cart 310. It is generally contemplated that various types of bases 214 may be used in the mobile robot station 212, including, for example, a stationary floor or a shiftable floor (such as a slidable or rollable floor). In one form, the base 214 of the mobile robot station 300 may be shifted with the mobile robot 301 resting on the base 214 such that the base 214 is moved atop the support surface 314 of the maintenance cart 310. In another form, the mobile robot 301 may be rolled onto the support surface 314 of the maintenance cart 310. In yet another form, the base 214 may be in the form of rails or other supports, and mobile robots 301 may move along these rails or supports from the mobile robot station 300 to the maintenance cart 310.

[0072] FIG. 4 again shows the mobile robot station 300 with the second gate 304 in an open position. The sliding bar 306 is in a first position in which downward movement of the first gate 302 is blocked. FIG. 4 shows the mobile robot station 300 with two sidewalls 316 enclosing the sides of the mobile robot station 300 and with a ceiling 318 covering the top of the station 300. FIG. 5 generally shows the mobile robot station 300 with the second gate 304 in an open position, but without the sidewalls 316 and ceiling 318 of FIG. 4.

[0073] FIG. 6 shows the mobile robot station 300 with the first gate 302 in an open position. The sliding bar 306 has been shifted rearward (back toward the second gate 304) so that it is in a second setting. This shift of the sliding bar 306 allows the first gate 302 to move downward but simultaneously blocks movement of the second gate 304. FIG. 6 shows the mobile robot station 300 with the two sidewalls 316 (which may be modified to include cutout portions 317) enclosing the sides of the mobile robot station 300 and with a ceiling 318 covering the top of the station 300. FIG. 7 generally shows the mobile robot station 300 with the first gate 302 in an open position and the second gate 304 in a closed position, but without the sidewalls 316 and ceiling 318 of FIG. 6.

[0074] In some forms, it is generally contemplated that the sliding bar 306 may occupy three different settings such that the mobile robot station 300 is in three different states. In a first setting, the sliding bar 306 blocks downward movement of the first gate 302 (first gate closed), while allowing downward movement of the second gate 304 (second gate open). In a secondsetting, the sliding bar 306 allows downward movement of the first gate 302 (first gate open), while blocking downward movement of the second gate 304 (second gate closed). However, it is further contemplated that there may be an intermediate, third setting in which the sliding bar 306 blocks downward movement of both the first and second gates 302, 304 (first and second gates closed). This intermediate, third setting may be desirable to completely isolate the mobile robot 301 such as, for example, to allow deactivation of the mobile robot 301.

[0075] Although the use of a bar has been provided as one example of a gate control mechanism, other types of gates and other gate control mechanisms are also contemplated. For example, vertically pivoting gates, swing gates, horizontally sliding gates, retractable gates, foldable gates, etc., are contemplated. Other gate control mechanisms, such as various latching and locking mechanisms, etc., are also contemplated. These other types of gates and gate control mechanisms allow, at least, the alternating between the first two settings / states described above. Also, optionally, they may allow alternating with the third, intermediate setting / state described above.

[0076] FIGS. 8-16 show the mobile robot station 300 with some additional optional features. FIGS. 8 and 9 show the first gate 302 (or inner gate) in a closed position and then in an open position. In this form, it is contemplated that the mobile robot station 300 may include two bot blockers 324 on either side of the mobile robot station 300. In one form, these bot blockers 324 may be incorporated into a rail structure 325 along which mobile robots 301 travel, and they may be in an engaged position in which they may block wheels 312 (or other motion mechanisms) of the mobile robot 301 so as to either block entry or exit of the mobile robot 301. As one example, these bot blockers 324 may be metal components and / or frictional material that may be introduced into, or removed from, the path of the mobile robot 301. Examples of bot blockers, and further details relating to the structure and operation of bot blockers, are disclosed in PCT Publication No. WO 2024 / 076682, which publication is incorporated by reference herein in its entirety. In FIG. 8, the first gate 302 is closed and the bot blockers 324 are engaged. In FIG. 9, the first gate 302 is open. In this open position, rollers 326 on the first gate 302 have been used to disengage the bot blockers 324 so that they are no longer blocking entry or exit of the mobile robot 301.

[0077] Next, FIGS. 10-13 show the use of optional features on the maintenance cart 310 (or transport cart) to cooperate with the second gate 304 (or outer gate). This form also includesbot blockers 328 that can be engaged to block the mobile robot 301 and that can be disengaged to allow movement of the mobile robot 301. In this form, however, the second gate 304 does not include rollers or some other mechanism that disengages bot blockers 328 when the second gate 304 is lowered.

[0078] Instead, the maintenance cart 310 must be docked in order to disengage the bot blockers 328. In one form, as can be seen in FIGS. 10 and 11, the support surface 314 of the maintenance cart 310 may include two projecting portions or flanges 330 extending on both sides of the support surface 314. These flanges 330 may directly engage bot blockers 328 to cause them to move from a blocking position to a non-blocking position. Alternatively, these flanges 330 may engage a mechanism that, in turn, causes movement of the bot blockers 328 from the blocking position to the non-blocking position.

[0079] In FIG. 12, the second gate 304 is open, but the bot blockers 328 are still in a blocking position (the maintenance cart 301 is not yet in position). In FIG. 13, the support surface 314 has been inserted so that the projecting portions / flanges 330 have caused the bot blockers 328 to move to a non-blocking position (the maintenance cart 301 is in position). The use of these projecting portions / flanges 330 helps ensure that the mobile robot 301 cannot exit through the open second gate 304 until the maintenance cart 301 is in a position to receive the mobile robot 301.

[0080] FIGS. 14-16 show an additional optional feature in the form of an access port 332. This access port 332 is positioned on one of the sides of the mobile robot station 301 and may allow a technician to access the mobile robot 30, such as, for example, to perform maintenance or repair on the mobile robot 301 or retrieve a container from the mobile robot 301. In one form, this access port 332 may be coupled to an open or closed state of a gate. As one example, in one form, this access port 332 can only be opened while the first gate 302 is closed.

[0081] FIGS. 14-16 show an example of operation of the access port 332 depending on the state of the gates 302 and 304. In FIG. 14, if the first gate 302 (inner gate) is open, the mechanical interlock requires the second gate 304 (outer gate) to be closed, and with the second gate 304 closed, the second gate handle 334 blocks the access port 332 from opening. More specifically, an access port cover 333 blocks the access port 332, and the second gate handle 334 blocks the access port cover 333 from moving downwardly along slots 335 to an open position. In FIG. 15,with the second gate 304 open, the second gate handle 334 is down, and the access port cover 333 is free to move downwardly so that the access port 332 can open. In FIG. 16, the access port cover 333 has been moved downwardly, and the access port 332 is open. In one form, the second gate 304 cannot be closed without first closing the access port 332, and the first gate 302 can only be opened if both the second gate 304 and the access port 332 are closed. Optionally, a graphic user interface (GUI) 336 may be included on the housing adjacent the access port 332.

[0082] FIGS. 17 and 18 show another example of a mobile robot station 400. In this form, the mobile robot station 400 uses a single-piece rotary cover lid 402 with front and rear portions that operate as the first and second gates, respectively. The rotary cover lid 402 can be rotated about a pivot axis 404 to open and close the first and second gates. The pivot axis 404 allows the rotary cover lid 402 to rotate such that portions of it are below the base 406 at different positions / states. FIG. 18 shows the mobile robot station 400 with sidewalls 408.

[0083] In a first position / state, the rotary cover lid 402 is rotated so that a portion of the rotary cover lid 402 blocks access from a front side (the first gate is closed), while the rotary cover lid 402 allows access from the rear side (the second gate is open). In a second position / state, as shown in FIGS. 17 and 18, the rotary cover lid 402 has been rotated about the pivot axis 404 such that the lid 402 allows access from the front side (the first gate is open), while a portion of the rotary cover lid 402 blocks access from the rear side (the second gate is closed). The size of the rotary cover lid 402 is preferably selected (and coordinated with the dimensions of the mobile robots) so that, when one side is open, the portion of the lid 402 on the other side is at a low enough height so as to block the mobile robot from exiting the other side. It is also contemplated that there may be a third, intermediate position / state. In this third position / state, the rotary cover lid 402 is positioned so that portions of it block both the front and rear sides (both the first and second gates are in closed positions).

[0084] FIGS. 19-22 show another example of a mobile robot station 500. In this form, the mobile robot station 500 uses a two-piece rotary cover lid 501 that includes two discrete and interlocking rotary lid cover portions 502, 504, i.e., it uses a front rotary cover lid portion 502 and a rear rotary cover lid portion 504. These front and rear rotary cover lid portions 502, 504 operate as the first and second gates, respectively. Each rotary cover lid portion 502, 504 can be separately rotated to open and close the first and second gates, respectively. In one form, the lid portions502, 504 may be in the nature of inner and outer shells that generally share the same axis of rotation.

[0085] In a first position / state, as shown in FIG. 20, the front rotary cover lid portion 502 is rotated so that it blocks access from a front side (the first gate is closed), while the rear rotary cover lid portion 502 is rotated so that it allows access from the rear side (the second gate is open). In a second position / state, as shown in FIG. 22, the front rotary cover lid portion 502 has been rotated such that it allows access from the front side (the first gate is open), while the rear rotary cover lid portion 502 has been rotated so that it blocks access from the rear side (the second gate is closed). The rotary cover lid portions 502, 504 are coordinated with one another so that, when one portion is in an open position on one side, the other portion cannot be moved to an open position on the other side. For example, in one form, when one portion has been rotated and locked into an open position, this positioning may mechanically block movement of the other portion. It is also contemplated that there may be a third, intermediate position / state, as shown in FIGS. 19 and 21. In this third position / state, both rotary cover lid portions 502, 504 are positioned so that they block both the front and rear sides (both the first and second gates are in closed positions).

[0086] Next, it is desirable to locate the mobile robot station (such as mobile robot stations 212, 300, 400, 500 described above) at a certain area of the facility 100. In one form, it is preferable to locate the mobile robot station at an area that does not interfere with the general movement and operation of mobile robots. In other words, it may be desirable to locate the mobile robot station at an area that may require mobile robots to navigate around it and where mobile robots are not at risk of running into it (and possibly damaging themselves and / or the station).

[0087] FIGS. 23-27 show a mobile robot receiving system 600 disposed adjacent a deck (or transit plane / area) 602. The mobile receiving system 600 includes a mobile robot station 604 and maintenance cart 606. In one form, the mobile robot receiving system 600 may include, without limitation, any of the mobile robot stations 212, 300, 400, 500 described above and components thereof. It is also contemplated that the mobile robot receiving system 600 may include, without limitation, the maintenance cart 310 described above and components thereof.

[0088] The figures show a portion of the facility 100 with some structural detail removed for clarity. FIG. 23 and FIG. 24 are similar to one another, but with some of the facility structure shown removed in FIG. 24. Mobile robots 608 move up and down the aisles 610 depositing and / orretrieving containers (or totes) at storage locations 612. The ends of the aisles 610 allow mobile robots 608 access to and from the decks 602. In this form, the decks 602 provide the mobile robots 608 with access to the mobile receiving system 600.

[0089] In this form, the mobile robot station 604 (and mobile robot receiving system 600) is disposed adjacent an end of the deck 602 with the mobile robot station 604 being off the deck 602 and bordering an edge of the deck 602. The mobile robot station 604 is preferably disposed so that a first gate 614 of the mobile robot station 604 allows access to a mobile robot 608 entering from the deck 602. Further, it is preferably disposed so that a second gate 616 of the mobile robot station 604 is adjacent the maintenance cart 606. As can be seen in FIG. 27, a base 618 of the mobile robot station 604 is preferably disposed at the same elevational level as the deck 602, which is preferably at the same elevation as a support surface 620 of the maintenance cart 606, so as to allow horizontal movement of the mobile robot 608 from the deck 602 to the mobile robot station 604 and to the maintenance cart 606. It is also contemplated that this general action may be reversed so as to introduce a new mobile robot 608 from the maintenance cart 606 (or from the mobile robot station 604) to the deck 602. In some forms, the mobile robot station 604 and / or the maintenance cart 606 may include an assembly 622 to allow adjustment of the height of the base 618 and / or support surface 620, respectively, to match that of the deck 602.

[0090] FIGS. 28-32 show a mobile robot receiving system 700 disposed adjacent the end of an aisle 710. The mobile receiving system 700 includes a mobile robot station 704 and maintenance cart 706. In one form, the mobile robot receiving system 700 may include, without limitation, any of the mobile robot stations 212, 300, 400, 500 described above and components thereof. It is also contemplated that the mobile robot receiving system 700 may include, without limitation, the maintenance cart 310 described above and components thereof.

[0091] Like FIGS. 23-27, FIGS. 28-32 show a portion of the facility 100 with some structural detail removed for clarity. Mobile robots 708 move up and down the aisles 710 depositing and / or retrieving containers (or totes) at storage locations 712. The ends of the aisles 710 allow mobile robots 708 access to and from the decks 702. In this form, the aisles 710 provide the mobile robots 708 with access to the mobile receiving system 700.

[0092] In this form, the mobile robot station 704 (and mobile robot receiving system 700) is disposed adjacent an end of an aisle 710 with the mobile robot station 704 being off the aisle710 and bordering an edge of the aisle 710. The mobile robot station 704 is preferably disposed so that a first gate 714 of the mobile robot station 704 allows access to a mobile robot 708 entering from the aisle 710. Further, it is preferably disposed so that a second gate 716 of the mobile robot station 704 is adjacent the maintenance cart 706. As can be seen, a base 718 of the mobile robot station 704 is preferably disposed at the same elevational level as the aisle 710, which is preferably at the same elevation as a support surface 720 of the maintenance cart 706, so as to allow horizontal movement of the mobile robot 708 from the aisle 710 to the mobile robot station 704 and to the maintenance cart 706. It is also contemplated that this general action may be reversed so as to introduce a new mobile robot 708 from the maintenance cart 706 (or from the mobile robot station 704) to the deck 702. In some forms, the mobile robot station 704 and / or the maintenance cart 706 may include an assembly 722 to allow adjustment of the height of the base 718 and / or support surface 720, respectively, to match that of the aisle 710.

[0093] FIGS. 33-38 show another example of a mobile robot receiving system 800. In this form, the mobile robot receiving system 800 includes a type of integrated mobile robot station 802 (or “smart cart”) that docks to a structure (without a separate maintenance cart). In the figures, the mobile robot station 802 can be seen docking to a deck 804 (or transit plane or transit area), although it is also contemplated that, in some circumstances, the mobile robot station 802 may also dock to the end of an aisle 806. As can be seen, the mobile robot station 802 preferably has some form of locomotion (such as wheels 808) to allow the mobile robot station 802 to dock at different desired locations of decks 804 and aisles 806. Once at the docking location, the mobile robot station 802 may then receive a mobile robot 810 and move to a maintenance area for servicing and repair.

[0094] FIGS. 33 and 34 show the mobile robot station 802. FIG. 33 shows the mobile robot station 802 with locomotion 808 to facilitate interfacing of the mobile robot station 802 with the end of the aisle 806 or deck 804 to position the mobile robot station 802 in a docking position. The mobile robot station 802 also includes a first blocking portion 812 and a second blocking portion 814 that generally serve as sidewalls when the mobile robot station 802 is receiving a mobile robot 810. The first and second blocking portions 812, 814 extend over the aisle 806 or deck 804 when the mobile robot station 802 is in the docking position. The mobile robot station 802 also preferably includes a base or support surface 816 for receiving a mobile robot 810 thereon.

[0095] FIG. 34 is a schematic diagram that shows the mobile robot station 802 with possible additional features. FIG. 34 shows the mobile robot station 802 in a docking position with a portion of the mobile robot station 802 extending over the deck 804. The mobile robot station 802 includes first and second blocking portions 812, 814 that may act as sidewalls. It further includes a first gate 818 that may be in an open position to receive the mobile robot 810 and then closed. It may further include a second gate 820 that may be moved between open or closed positions, although, in some forms, the second gate 820 need not be used. The mobile robot station 802 may also include one or more rail ramps 822 to facilitate movement of the mobile robot along the base or support surface 816 of the mobile robot station 802 and to help secure the mobile robot in the station 802. The mobile robot station 802 may also include a third blocking portion 824 at the rear of the mobile robot station 802 to block rearward movement of the mobile robot 810 once it has been received in the station 802.

[0096] In some forms, it is contemplated that the first gate 818 and one or more sensors 222 may be used to create a self-contained safety zone. Sensors 222, in conjunction with a control circuit 224, may be used to trigger opening of the first gate 818 to receive the mobile robot 810 and may then trigger closing of the first gate 818 after the mobile robot 810 has been received in the station 802. This mobile robot station 802 (smart cart) may allow for robot removal (and, in some instances, for robot introduction) into the work area without a permanent space claim to part of a deck 804 or aisle 806.

[0097] FIGS. 35-38 show several different stages in the reception of the mobile robot 810 in the mobile robot station 802. FIGS. 35 and 36 show the mobile robot 810 moving along the deck 804 in the direction of the docked mobile robot station 802. The mobile robot station 802 has its first and second blocking portions 812, 814 extended over the deck 804, and the first gate 818 is open. FIG. 37 shows the mobile robot 810 received in the station 802 through the open first gate 818, and FIG. 38 shows the first gate 818 in a closed position. The mobile robot 810 may then move to the base / support surface, and the mobile robot station 802 may then leave or undock from the deck 804.

[0098] FIGS. 39-47 show another example of a mobile robot receiving system 900. In this form, the mobile robot receiving system 900 includes a permanent mobile robot station 902 that is fixed at a location adjacent an end of the deck 904, although it is also contemplated that, in somecircumstances, the mobile robot station 902 may also be fixed at a location adjacent an end of an aisle 906. In effect, by adding a permanent structure to the end of the deck 904 (or an aisle 906), this example is adding an extension to the deck 904 (or aisle 906) and is thereby increasing the footprint of the deck 904 (or aisle 906).

[0099] In this form, it is generally contemplated that the mobile robot station 902 can be considered to act as a sort of rudimentary external airlock on the deck 904 (or aisle 906). With respect to the figures, the mobile robot station 902 has a first (or inner) gate 908 that controls access to and from the deck 904, and a second (or outer) gate 910 that controls external access. In some forms, as shown in FIG. 39, the mobile robot station 902 may optionally have sidewalls 912 to help ensure that the mobile robot 914 is secured in the station 902.

[0100] As addressed earlier, it is generally contemplated that both gates 908, 910 cannot be open at the same time. For safety, the first (inner) gate 908 should be closed before the second (outer) gate 910 can be opened. This condition may, for example, be accomplished by mechanical coupling and operation (such as by a sliding bar 306) or by electrical coupling and operation (such as by a control circuit 224 operating in conjunction with sensors 222 and software). Also, optionally, the operator may be required to turn off or deactivate the mobile robot 914 before opening the second (outer) gate 910, and / or the maintenance cart 916 may be required to be present before opening the second (outer) gate 910. The mobile robot station 902 may also include navigational aids disposed in its base 917, such as magnetic guidelines or RFID tags to allow the mobile robot 914 to know its positioning while it is active and to allow it to move into the mobile robot station 902.

[0101] FIGS. 40-47 show several different stages in the reception of the mobile robot 914 in the mobile robot station 902. FIGS. 40 and 41 show the mobile robot 914 moving in the direction of the mobile robot station 902. FIG. 42 shows the mobile robot 914 having entered the mobile robot station 902 through the open first gate 908, and following entry, FIG. 43 shows the first gate 908 being closed. FIGS. 44 and 45 show the second gate 910 opening and the maintenance cart 916 disposed adjacent the second gate 910 to receive the mobile robot 914 from the mobile robot station 902. It is also contemplated that this general action may be reversed so as to introduce a new mobile robot 914 from the maintenance cart 916 (or from the mobile robot station 902) to the deck 904.

[0102] Although FIGS. 40-45 show the mobile robot station 902 with gates 908, 910 that are located opposite from one another, these gate locations are not required. For example, FIGS. 46 and 47 show the second (outer) gate 910 and maintenance cart 916 being disposed on the lefthand side of the mobile robot station 902 so that the two gates 908, 910 are not facing one another. In one form, if the mobile robot station 902 uses a gate 910 on the side of the station 902, the base 917 may include a sliding platform to slide the mobile robot 914 onto the cart.

[0103] FIGS. 48-53 show another example of a mobile robot receiving system 1000. In this form, as can be seen in FIG. 48, the mobile robot receiving system 1000 includes a permanent mobile robot station 1002 that is installed at a dedicated location on the deck 1004, although it is also contemplated that, in some circumstances, the mobile robot station 1002 may also be installed at a dedicated location at an end of an aisle 1006. The mobile robot station 1002 is similar to the previously described station 902, but in this form, the station 1002 is installed on the deck 1004 (or in the aisle 1006), rather than next to an end of it. The mobile robot station 1002 is preferably located at an end of the deck 1004 (or aisle 1006) so that a maintenance cart 1016 can be disposed off the end of the deck 1004 (or aisle 1006). In this form, mobile robots 1014 may have to navigate around the mobile robot station 1002 on the deck 1004.

[0104] In this form, it is again contemplated that the mobile robot station 1002 may act as a sort of rudimentary external airlock on the deck 1004 (or aisle 1006). With respect to the figures, the mobile robot station 1002 has a first (or inner) gate 1008 that controls access to and from the deck 1004, and a second (or outer) gate 1010 that controls external access. It is generally contemplated that the mobile robot station 1002 may have sidewalls 1012 to help ensure that the mobile robot 1014 is secured in the station 1002.

[0105] Like station 902 described above, it is generally contemplated that both gates 1008, 1010 cannot be open at the same time. For safety, the first (inner) gate 1008 should be closed before the second (outer) gate 1010 can be opened. This condition may, for example, be accomplished by mechanical coupling and operation (such as by a sliding bar 306) or by electrical coupling and operation (such as by a control circuit 224 operating in conjunction with sensors 222 and software). Also, optionally, the operator may be required to turn off or deactivate the mobile robot 1014 before opening the second (outer) gate 1010, and / or the maintenance cart 1016 may be required to be present before opening the second (outer) gate 1010. The base 1017 of the mobilerobot station 1002 may either be a part of the deck 1004 or may be a separate surface installed on top of the deck 1004. In either circumstance, the base 1017 may also include navigational aids disposed therein, such as magnetic guidelines or RFID tags to allow the mobile robot 1014 to know its positioning while it is active and to allow it to move into the mobile robot station 1002.

[0106] FIGS. 49-53 show several different stages in the reception of the mobile robot 1014 in the mobile robot station 1002. FIGS. 49 and 50 show the mobile robot 1014 moving in the direction of the mobile robot station 1002. FIG. 51 shows the mobile robot 1014 having entered the mobile robot station 1002 through the open first gate 1008, and following entry, FIG. 52 shows the first gate 1008 being closed. FIG. 53 shows the second gate 1010 opening and the maintenance cart 1016 disposed adjacent the second gate 1010 to receive the mobile robot 1014 from the mobile robot station 1002. It is also contemplated that this general action may be reversed so as to introduce a new mobile robot 1014 from the maintenance cart 1016 (or from the mobile robot station 1002) to the deck 1004. In one form, optionally, the mobile robot station 1002 may be constructed so that it may be rotated out of the way when not in use so that it is no longer over the deck 1004 (or over an aisle 1006).

[0107] FIGS. 54-57 show another example of a mobile robot receiving system 1100. This system 1100 uses a different approach than the systems described above. In this form, as can be seen in FIG. 54, the mobile robot receiving system 1100 includes a mobile robot station 1102. The mobile robot station 1102 includes a form of locomotion 1104, a height adjustment assembly 1106 to allow a base or support surface 1108 to be raised to different heights (such as a jack). The mobile robot station 1102 also includes one or more forklift tines or arms 1110 (preferably two arms 1110) that are attached to and supported by the base / support surface 1108. The arms 1110 are intended to support and lift the mobile robot 1112 so that it can be removed from the internal work area 1114 (such as from a deck or from an aisle). Optionally, although not required, the arms 1110 may be extendable and retractable so that they can move a lifted mobile robot 1112 back onto the base / support surface 1108.

[0108] As can be seen in the figures, it is generally contemplated that the facility 100 has a barrier 1116 that separates at least some of the internal work area 1114 from an external area 1115 that may be frequented by individuals / operators. In other words, generally, mobile robots 1112 move within the internal work area 1114, while individuals move within the external area1115. The barrier 1 116 (such as a wall or fence) prevents mobile robots 1112 from leaving the internal work area 1114. The barrier 1116 includes a number of slots (or cutouts) 1118 corresponding to the number of arms 1110 (preferably two slots 1118).

[0109] FIGS. 55-57 show several stages of the operation of the mobile robot station 1102 in retrieving a mobile robot 1112 (or in introducing one into the internal work area 1114). Initially, the mobile robot 1112 moves and positions itself at the end of the internal work area 1114 next to the slots 1118. The mobile robot station 1102 also moves and positions itself next to the slots 1118 but on the other side of the barrier 1116 (on the external area side of the barrier 1116). FIG. 55 shows the mobile robot station 1102 extending the arms 1110 through the slots 1118 and underneath the mobile robot 1112. FIG. 56 shows the mobile robot station 1102 lifting the mobile robot 1112 above the top of the barrier 1116 via operation of the height adjustment assembly 1106. FIG. 57 shows the mobile robot station 1102 moving back into the external area 1115 so as to move the mobile robot 1112 into the external area 1115 over the barrier 1116. This general action may be reversed to introduce mobile robots 1112 from the external area 1115 into the internal work area 1114. This approach allows for mobile robot removal and introduction without any additional structure to either the internal work area 1114 or the external area 1115.

[0110] FIG. 58 shows a process 1200 for using a mobile robot station (or bot station) to receive a mobile robot (or bot) from a work area. It is generally contemplated that the bot may be received from a deck area or from an aisle. Further, it is generally contemplated that the bot station may be any of the mobile robot stations and involve some or all of the components described above, such as, for example, mobile robot stations 212, 300, 400, 500, 604, 704, 802, 902, and 1002. It is also generally contemplated that certain actions, as indicated in FIG. 58, may be performed by or may involve different actors / devices, such as operator action 1226, bot system action 1228, and sensor confirmation action 1230.

[0111] At block 1202, an operator requests that a bot be removed. It is generally contemplated that the there has been some indication that the bot needs to be repaired, replaced, or receive routine maintenance. For example, this indication may involve bot sensor readings and communication from the bot itself to an external / remote control circuit. As an alternative, an external control circuit may be monitoring the bot sensor readings and may determine that the bot requires servicing. As a further alternative, the bot may be determined to be operating erratically,or it may be approaching a predetermined time since its last servicing or maintenance. The phrase “control circuit” has been addressed above, and in one form, it is contemplated that the extemal / remote control circuit may be a centralized control circuit that is remote from the bots. Further, it is contemplated that the centralized control circuit may generally be in communication with the various bots.

[0112] At block 1204, the bot station internal (first) gate opens. In FIG. 58, this action is shown to be performed by an operator, although it is also contemplated that, in some forms, this action may be performed automatically (such as in response to a proximity sensor). As addressed above, it is contemplated that when the internal (first) gate is in an open position, an external (second) gate is blocked from moving to an open position.

[0113] At block 1206, a routing system (such as a navigation and / or communication system) routes the bot to the bot stations. In some forms, it is contemplated that the bot is controlled externally and is instructed to proceed to the bot station. In other forms, it is contemplated that the bot uses an internal routing system to navigate autonomously to the bot station.

[0114] At block 1208, when the bot arrives at the bot station, the bot’s location within the bot station is confirmed. In one form, it is contemplated that the bot station may include a sensor configured to detect reception of the bot in the mobile robot station. Any of various types of sensors may be used, including, for example, weight sensors, proximity sensors, pressure sensors, motion detectors / sensors, position sensors, etc. Depending on the type of sensor, it may be located at the bot station or it may be disposed at a remote location. These sensors may be coupled to, or coordinated with, the internal (first) and external (second) gates so as to trigger their opening and closing based on the position of the bot.

[0115] Additionally or alternatively, in some forms, it is contemplated that an external / remote control circuit may confirm or receive confirmation of the position of the bot in the bot station. In one form, the control circuit may confirm or receive confirmation that the bot is properly received in the bot station via positional data. This positioning confirmation may be accomplished in various ways. For example, positional data may be obtained from a bot’s motor encoders, which may be used to confirm its location relative to observed fiducials of the bot.Additionally, a mobile robot may use its RFID reader(s), camera(s), and / or other devices to establish its position, as alternative or additional levels of positional confirmation.

[0116] At block 1210, after the bot has been properly received in the bot station, the internal (first) gate closes. In some forms, both the internal (first) gate and the external (second) gate (second) will be in closed positions. At block 1212, an operator manually turns off the bot, such as by manually triggering a switch on an access panel of the bot. In other forms, however, it is contemplated that the bot may deactivate itself or that a remote control circuit may instruct the bot to deactivate itself.

[0117] At block 1214, the operator may dock the maintenance cart to the bot station, preferably adjacent the external (second) gate. As an example, any of the various maintenance carts described above may be used, and it is generally contemplated that the cart is docked so that the bot can be easily transferred from the bot station to the cart. At block 1216, sensor(s) are preferably used to confirm that the internal (first) gate is closed (and optionally that the cart is properly docked). Any of the various sensors and / or positional approaches described above may be used.

[0118] At block 1218, the external (second) gate of the bot station is unlocked. It is generally contemplated that some mechanical or control circuit / software mechanism, such as described above, is used to lock the external (second) gate and prevent it from opening when the internal (first) gate is in an open position. Now, when the internal (first) gate is in a closed position, this mechanism no longer prevents opening of the external (second) gate. At block 1220, the operator opens the external (second) gate. Alternatively, in other forms, it is contemplated that the opening of the external (second) gate may be triggered, such as by sensors and / or by instructions from a control circuit.

[0119] At block 1222, the operator manually rolls (or otherwise moves) the bot onto the cart. In one form, it is contemplated that the operator may connect a brake box to the bot and may then manually roll the bot onto the cart. At block 1224, after the bot has been moved to the cart, the operator may close the external (second) gate and remove the cart from the bot station. The operator may then move the cart with the bot thereon to a maintenance or servicing area.

[0120] FIG. 59 shows a process 1300 for using a mobile robot station (or bot station) to introduce (or induct) a mobile robot (or bot) into a work area. It is generally contemplated that thebot may be introduced from a secure external area where individuals are present and where bots are not operating. It is generally contemplated that the bot may be introduced onto a deck area or onto an aisle of the work area where bots are operating.

[0121] Many of the actions are similar to, but performed in a reverse order, from those described above in connection with the bot removal process 1200. The description of process 1200 is generally incorporated herein, and the induction process 1300 may be modified in a manner consistent therewith. Again, it is generally contemplated that the bot station may be any of the mobile robot stations and involve some or all of the components described above, such as, for example, mobile robot stations 212, 300, 400, 500, 604, 704, 802, 902, and 1002. Further, certain actions, as indicated in FIG. 59, may be performed by or may involve different actors / devices, such as operator action 1326, bot system action 1328, and sensor confirmation action 1330.

[0122] At block 1302, the operator may dock a maintenance cart carrying a bot to a bot station, preferably adjacent an external (second) gate. As an example, any of the various maintenance carts described above may be used, and it is generally contemplated that the cart is docked so that the bot can be easily transferred from the bot station to the cart. In other words, the operator transports a bot (preferably deactivated) toward a bot station disposed proximate an edge of a pathway or a deck. At block 1304, the operator opens the external (second) gate. As addressed above, it is contemplated that when the external (second) gate is in an open position, the internal (first) gate is blocked from moving to an open position. Alternatively, in other forms, it is contemplated that the opening of the external (second) gate may be triggered, such as by sensors and / or by instructions from a control circuit.

[0123] At block 1306, the operator manually rolls (or otherwise moves) the bot from the cart into the bot station. In other words, the operator moves the bot through the open external (second) gate of the bot station and onto a base of the bot station with the external (second) gate being movable between an open position and a closed position. In one form, it is contemplated that the operator may use a brake box to manually move the bot onto the cart.

[0124] At block 1308, after the bot has been moved into the bot station, the operator may close the external (second) gate. Alternatively, in other forms, it is contemplated that the closing of the external (second) gate may be triggered, such as by sensors and / or by instructions from a control circuit. In some forms, both the internal (first) gate and the external (second) gate (second)will be in closed positions. In some forms, it is contemplated that the hot may be charged while it is in the station prior to introduction into the work area. At block 1310, an operator manually turns on the bot, such as by manually triggering a switch on an access panel of the bot. In other forms, however, it is contemplated that a remote control circuit may activate or energize the bot.

[0125] At block 1312, the bot’s location within the bot station is confirmed. As described above, in one form, it is contemplated that the bot station may include a sensor configured to detect the location of the bot in the mobile robot station, and any of various types of sensors may be used. These sensors may be coupled to, or coordinated with, the internal (first) and external (second) gates. Additionally or alternatively, in some forms, it is contemplated that an extemal / remote control circuit may confirm or receive confirmation of the position of the bot in the bot station. In one form, the control circuit may confirm or receive confirmation that the bot is properly located in the bot station via positional data, which positioning confirmation may be performed in various ways, as described above.

[0126] At block 1314, the bot station internal (first) gate opens with the internal (first) gate being movable between an open position and a closed position. In FIG. 59, this action is shown to be performed by an operator, although it is also contemplated that, in some forms, this action may be performed automatically (such as in response to a sensor and / or control circuit). It is generally contemplated that the internal (first) gate provides the bot with access to the pathway or deck to allow the bot to move along the pathway or deck. As addressed above, it is contemplated that when the internal (first) gate is in an open position, an external (second) gate is blocked from moving to an open position. In other words, one of the external and internal gates is preferably blocked from moving to an open position when the other of the external and internal gates is in an open position. At block 1316, the operator may request permission for induction (or introduction) of the bot into the work area.

[0127] At block 1318, the opening of the internal (first) gate is confirmed. In some forms, it is contemplated that sensor(s) are coupled to, or coordinated with, the internal (first) gate to confirm that it is in an open position. At block 1320, a routing system routes the bot to a desired location within the facility. In some forms, it is contemplated that the bot is controlled externally and is instructed to proceed to the bot station. In other forms, it is contemplated that the bot usesan internal routing system to navigate autonomously to the hot station. At block 1322, the operator closes the internal (first) gate and removes the cart from the hot station.

[0128] It is generally contemplated that the above-described mobile robot stations and processes are designed so as to ensure the safety of individuals within the facility. For example, in some forms, it is contemplated that safety sensors may be used to e-stop the entire system (or part of the system) if a gate is detected to be in an incorrect position. The inner (first) gate may include a safety sensor that detects the state / position of the inner gate, and the outer (second) gate may also include a safety sensor that detects the state / position of the outer gate. In turn, both of these safety sensors may be coupled to a safety programmable logic controller (PLC). If the safety PLC determines that either of the two safety sensors indicates an incorrect and / or unsafe position for either gate, it may e-stop the system.

[0129] FIGS. 60-65 generally show another example of a mobile robot receiving system 1400 and mobile robot station 1402. It is generally contemplated that mobile robot station 1402 can be used to isolate and remove a mobile robot that may be damaged or require some sort of maintenance. It is also contemplated, however, that this system 1400 may involve additional capabilities, such as acting as a picking, dispensing, and / or decanting workstation in which products and / or containers (such as totes) may be removed from or deposited with a mobile robot. This example of a mobile robot station 1402 may act as a sort of universal workstation with multiple potential uses. It is generally contemplated that this mobile robot station 1402 may utilize one or more components of the previously-described mobile robot stations, except to the extent inconsistent herewith.

[0130] In one form, the mobile robot station 1402 includes at least one gate (and preferably includes two gates) in the form of a pivotable / hinged cover portion (or clam shell structure). In some forms, the gate(s) may be pivotable about an axis / hinge between an open position and a closed position. In some forms, the gate(s) may be pivotable about one or more pivot axes. In some forms, the gate(s) may be sprung or counterbalanced to facilitate movement between open and closed positions. It is also contemplated that the gate(s) may be latched or locked into position after pivoting to either the open or closed positions, such as manually or by a control circuit.

[0131] The mobile robot station 1402 includes a first gate 1404 that is at (and defines) an entrance 1405 of the mobile robot station 1402. This first gate 1404 is accessible to a mobile robot1406 moving along a pathway or deck 1416. The first gate 1404 is movable between a first position and a second position such that the mobile robot 1406 can move into or out of the mobile robot station 1402 via the entrance 1405 when in the first position and such that the mobile robot 1406 is blocked from moving into or out of the mobile robot station 1402 via the entrance 1405 when in the second position.

[0132] The mobile robot station 1402 also preferably includes a second gate 1410 that is movable between an open position and a closed position. The second gate 1410 is at (and defines) an exit 1411 of the mobile robot station 1402. The second gate 1410 is movable between a third position and a fourth position such that the mobile robot 1406 can be moved into or out of the mobile robot station 1402 via the exit 1411 when in the third position and such that the mobile robot 1406 cannot be moved into or out of the mobile robot station 1402 via the exit 1411 when in the fourth position.

[0133] FIGS. 60-63 show the mobile robot station 1402 in three different states. FIGS. 60 and FIG. 63 show a first state in which the mobile robot 1406 can move through an entrance 1405 into the mobile robot station 1402. In FIGS. 60 and 63, the first gate 1404 is in the first position, and the second gate 1410 is in the fourth position. In this orientation, a mobile robot 1406 can enter the mobile robot station 1402 through the entrance 1405 but cannot otherwise exit. Further, user access to the volume of the mobile robot station 1402 is blocked such that a user cannot insert and remove items to and from the container carried by the mobile robot 1406 within the mobile robot station 1402. In one form, in this first state, the first gate 1404 acts as a covering portion to block user access.

[0134] FIG. 61 shows the mobile robot station 1402 in a second state. As can be seen, in this second state, the first gate 1404, which may be in the form of a first cover portion, has been pivoted about an axis 1412 to block the entrance and to confine the mobile robot 1406 within the mobile robot station 1402. This second state also blocks other mobile robots 1406 from entering the station 1402. In FIG. 61, the first gate 1404 is now in the second position, but the second gate 1410 is still in the fourth position. When the first gate 1404 is in this second position, user access to the volume of the mobile robot station 1402 is provided such that the user can insert and remove items to and from a container carried by the mobile robot 1406 within the mobile robot station 1402 (or can insert and remove the containers themselves). In other words, the first gate 1404,which may include a first cover portion, is configured to selectively allow and block access to a container carried by the mobile robot 1406 when the mobile robot 1406 is in the mobile robot station 1402.

[0135] With the second gate 1410 still in the fourth position, it is contemplated that a wall / barrier 1414 still exists between the mobile robot 1406 in the station 1402 and the user. As can be seen, in this form, the wall / barrier 1414 generally surrounds the mobile robot 1406 on three sides (and the first gate 1404 blocks the entrance on the fourth side). This barrier 1414 provides safety and protection to the user in this second state. Additional mobile robot features may be utilized for ensuring user safety, such as, for example, requiring pinions to be extended and in engagement with certain structure of the mobile robot station 1402. In one form, the mobile robot station 1402 may act as a workstation in which items in containers (or totes), or the containers themselves, are transferred to or from the mobile robot 1406 occupying the station 1402. For example, a user can perform operations such as picking or dispensing eaches from a container or decanting items into the container or bagging the container therein.

[0136] FIG. 62 shows the mobile robot station 1402 in a third state. As can be seen, in this third state, the second gate 1410, which may be in the form of a second cover portion, has been pivoted about the axis 1412 allowing user access to remove the mobile robot 1406 from the mobile robot station 1402. In one form, the first and second gates 1404, 1410 may be pivotable about the same axis 1412. Alternatively, in other forms, the first and second gates 1404, 1410 may be configured so as to be pivotable about different axes, not the same axis.

[0137] In FIG. 62, the first gate 1404 is still in the second position, but the second gate 1410 is now in the third position. When the second gate 1410 is in this third position, a user can remove the mobile robot 1406 via the exit 1411. In other words, the second gate 1410, which may include a second cover portion, is configured to selectively reveal and block the exit 1411 of the mobile robot station 1402. In some forms, it may be desirable to require that the mobile robot 1406 be deactivated prior to allowing the mobile robot station 1402 to be converted to this third state, i.e., prior to pivoting the second gate 1410 from the fourth position to the third position. For example, a programmable logic controller (PLC) may be used to prevent pivoting of the second gate 1410 until the mobile robot 1406 has been deactivated. Generally, some form of interlocked safety device(s) may be used controlling access for the performance of certain actions, such asremoval of the mobile robot 1406. Further, it may also be desirable to only provide approved technicians with the authority to remove the mobile robot 1406. Alternatively, it should also be understood that a mobile robot 1406 may be inducted (or introduced) via the exit 1411 when the mobile robot station 1402 is in this third state.

[0138] In some forms, such as shown in FIGS. 60-65, the first and second gates 1404, 1410 may include first and second cover portions such that one is nested within the other (forming a double clam shell). In one nested form, for example, the second gate 1410 cannot be moved unless the first gate 1404 has been pivoted from the first position to the second position. Alternatively, in other forms, the first and second gates 1404, 1410 may be configured so that they can be moved independently of one another. Further, in some forms, it is contemplated that the gates 1404, 1410 may be moved manually and / or may involve the use of sensors 222 and / or control circuits 224, as described above.

[0139] FIGS. 63-65 show additional view of the mobile robot receiving system 1400 and mobile robot stations 1402. FIG. 63 shows a mobile robot station 1402 in the first state where the entrance 1405 is open. The mobile robot station 1402 may include a bridge or arch 1415 defining the entrance 1405 that pivots as part of the first gate 1404 or about which the first gate 1404 pivots. FIG. 64 shows a mobile robot station 1402A that is in the first state next to another mobile robot station 1402B that is in the third state. FIG. 65 shows a mobile robot station 1402C that is in the first state next to another mobile robot station 1402D that is in the second state.

[0140] As can be seen, the mobile robot stations 1402 may be disposed at or near the edge of a deck 1416 (or transit area / plane). In some forms, a mobile robot station 1402 may be positioned toward the end of a deck 1416, or a deck 1416 may be further extended to accommodate a mobile robot station 1402. For example, an extended area 1417 may stretch along an X -direction next to the deck 1416 and may be composed of one or more panels. This extended area 1417 may include horizontal rails in the station 1402 for efficient transition in and out of the station 1402 via the deck 1416.

[0141] FIGS. 66 and 67 show how the mobile robot stations 1402 may be positioned outside of the general traffic flow of mobile robots 1406 at a facility 1422. It is generally contemplated that mobile robots 1406 may move along horizontal pathways 1418 to a vertical pathway 1420 and may then descend to a deck 1416. Two mobile robot stations 1402 may belocated at an edge of the deck 1416 so that they are generally out of the traffic flow of mobile robots 1406 using the deck 1416. In one form, as shown by arrows in FIG. 67, the mobile robots 1406 may travel in generally the same direction along the horizontal pathways 1418 at different levels, may then merge from their tiers / levels and travel downward along the vertical pathway 1420 to a different tier / level, and may then each enter and occupy a mobile robot station 1402 at that tier / level. If the mobile robots 1406 undergo a picking, dispensing, or decanting operation and are to remain in active operation in the system, they may then move back out through the entrance and head in the direction opposite from which they approached the mobile robot station 1402. This general traffic flow of mobile robots 1406 may help avoid traffic congestion.

[0142] FIGS. 68 and 69 show examples of how mobile robot stations 1402 may be strategically located at desired sites about a facility 1422. FIG. 68 shows two sets of mobile robot stations 1402 positioned at the opposite ends of decks 1416A to seek to limit mobile robot traffic congestion. Mobile robot stations 1402 may be disposed at ends of workstation decks 1416A so that they are generally outside of the ordinary traffic flow of mobile robots 1406. In FIG. 68, as can be seen, on each workstation deck 1416A, there are four mobile robot stations 1402, each set of two stations 1402 disposed at an end of the deck 1416A. Other decks may be express decks 1416B without mobile robot stations 1402, allowing mobile robots 1406 to move between aisles 1424, and may be distributed strategically at the facility 1422. As can be seen, the two workstation decks 1416A are interrupted in the middle to allow locations for mobile robot stations 1402 (in contrast to the uninterrupted express deck 1416B).

[0143] FIG. 69 shows how mobile robot stations 1402 may be disposed at different levels of the facility 1422. The mobile robot stations 1402 may be used for various purposes. It should be understood that the mobile robot stations 1402 may be used as removal / induction stations only, as decanting / dispensing / picking stations only, or as universal stations allowing for both removal / induction and decanting / dispensing / picking. FIG. 69 generally shows the mobile robot stations 1402 organized in pairs about the facility 1422, but, as should be understood, other arrangements are possible. The specific use of a mobile robot station 1402 may help determine its location within the facility 1422. For example, it may be desirable to dispense products or containers on the first floor of the facility 1422, such as after a shipment arrives, so some or all ofthe mobile robot stations 1402 on the first floor may be dedicated to dispensing products or containers to mobile robots 1406.

[0144] FIG. 70 shows a process 1500 for using a mobile robot station to receive a mobile robot from a work area. It is contemplated that the mobile robot may be involved in a picking / dispensing / decanting in the station in which items or containers are removed from or deposited with the mobile robot. Alternatively, it is contemplated that the station may be used for safe removal of the mobile robot from the work area. Further, it is generally contemplated that the mobile robot station may involve some or all of the components of mobile robot station 1402, and the above description of the mobile robot station 1402 is incorporated herein.

[0145] At block 1502, the mobile robot enters the mobile robot station via the entrance to the station. In the process 1500, in one form, it is contemplated that the mobile robot station includes two gates, and the first gate is in the first position and the second gate is in the fourth position described above. In this state, it is generally contemplated that the only open area is the entrance of the station. Further, in this state, the mobile robot may perform several operations that do not involve picking / dispensing / decanting in the station or safe removal, such as using the station for recharging and / or using it as a parking lot outside the general flow of mobile robot traffic in the work area. Following performance of these other operations, the mobile robot may, at some point, leave the station via the entrance.

[0146] At block 1504, the mobile robot is deactivated. In one form, the mobile robot may be deactivated as a safety measure prior to either a picking / dispensing / decanting operation or to controlled removal of the mobile robot itself from the station and work area via an exit to the station. It is generally contemplated that this deactivation step may occur at various stages in the process 1500. For example, in one form, this deactivation step may be performed later in the process 1500 after a user can access the mobile robot from above and can manually deactivate the mobile robot. In other forms, there may be remote deactivation, such as communicated to the mobile robot via a control circuit.

[0147] At block 1506, the first gate is moved to a position blocking the entrance of the station, assuming that a picking / dispensing / decanting operation or mobile robot removal operation is to be performed. It is generally contemplated that the first gate includes a first cover portion and that the first gate may be pivoted from the first position to the second position described above.In this state, it is contemplated that the first gate and the second gate collectively define a four wall barrier that surrounds the mobile robot but that the mobile robot station is uncovered to allow access to a user.

[0148] At block 1508, a user may pick, dispense, or decant items and / or containers. For example, the user may pick items from a tote or other container being transported by the mobile robot (or may pick the tote or container itself). Additionally, or as an alternative example, the user may deposit items in a tote or other container being transported by the mobile robot (or may deposit the tote or container itself with the mobile robot). It should be understood that this is an optional step. If the sole purposes for use of the station are for safe removal of the mobile robot from the work area or for temporary parking or recharging, this step need not be performed.

[0149] At block 1510, the mobile robot may be reactivated, assuming that a picking / dispensing / decanting operation has been performed and completed. This step may be performed in various stages of the process. In one form, it is contemplated that the mobile robot station is uncovered, and the user manually reactivates the mobile robot. In other forms, there may be remote reactivation via a control circuit.

[0150] At block 1512, the mobile robot recharges in the station. Although this recharging may be performed at various stages in the process, in one form, it may performed following reactivation after completion of a picking / dispensing / decanting operation. Further, at block 1514, the first gate may be moved from the second position back to the first position, which again covers the station but also opens the entrance to the station. The mobile robot may leave through the entrance of the station.

[0151] At blocks 1516 and 1518, it is contemplated that a mobile robot removal operation is to be performed (rather than picking / dispensing / decanting). In this form, blocks 1508-1512 may have been skipped. At block 1516, the second gate is moved to expose the exit. In one form, the second gate is pivoted from a fourth position (blocking the exit) to a third position (exposing the exit), as was described above. At block 1518, the user removes the mobile robot. In some forms, it is contemplated that only an authorized user / technician will perform this removal and / or that the second gate may not be shiftable unless the mobile robot is deactivated. Following removal of the mobile robot, the first and second gates may be moved back to their original positions such that the entrance is open and another mobile robot may use the station.

[0152] Those skilled in the art will recognize that a wide variety of other modifications, alterations, and combinations can also be made with respect to the above-described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.

Claims

CLAIMSWhat is claimed is:

1. A mobile robot receiving system comprising: a pathway or a deck configured to facilitate movement of mobile robots along the pathway or deck; a mobile robot station proximate an edge of the pathway or deck, the mobile robot station comprising: a first gate at an entrance of the mobile robot station and accessible to a mobile robot moving along the pathway or deck, the first gate movable between a first position and a second position, wherein the mobile robot can move into or out of the mobile robot station via the entrance when in the first position, wherein the mobile robot is blocked from moving into or out of the mobile robot station via the entrance when in the second position.

2. The mobile robot receiving system of claim 1, wherein the mobile robot station comprises: a second gate at an exit of the mobile robot station, the second gate movable between a third position and a fourth position, wherein the mobile robot can be moved into or out of the mobile robot station via the exit when in the third position, and wherein the mobile robot cannot be moved into or out of the mobile robot station via the exit when in the fourth position.

3. The mobile robot receiving system of claim 2, wherein the first gate and the second gate are configured such that: the first gate is blocked from moving to the first position when the second gate is in the third position; and the second gate is blocked from moving to the third position when the first gate is in the first position.

4. The mobile robot receiving system of claim 2, wherein:the mobile robot station further comprises a bar; the first gate comprises a first plate configured to move vertically between an upward position and a downward position; the second gate comprises a second plate configured to move vertically between an upward position and a downward position; and the bar is configured to move horizontally between a first setting and a second setting, the bar blocking vertical movement of the first plate in the first setting and blocking vertical movement of the second plate in the second setting.

5. The mobile robot receiving system of claim 2, wherein the mobile robot station further comprises a rotary cover lid, the rotary cover lid comprising a first portion that is rotatable to open and close the first gate and a second portion that is rotatable to open and close the second gate.

6. The mobile robot receiving system of claim 1, wherein the mobile robot station further comprises: a locomotion system configured to facilitate interfacing of the mobile robot station with the edge of the pathway or deck to position the mobile robot station in a docking position; a first blocking portion and a second blocking portion, the first and second blocking portions configured to extend over the pathway or deck when the mobile robot station is in the docking position; and a rail ramp configured to allow movement of a mobile robot along a base of the mobile robot station.

7. The mobile robot receiving system of claim 2, further comprising a maintenance cart disposed adjacent the second gate of the mobile robot station, the maintenance cart disposed to facilitate transfer of the mobile robot from the mobile robot station to the maintenance cart.

8. The mobile robot receiving system of claim 2, further comprising a control circuit operatively coupled to the first gate and the second gate, the control circuit configured to limitmovement of the first gate when the second gate is in the third position and to limit movement of the second gate when the first gate is in the first position.

9. The mobile robot receiving system of claim 1, wherein, when the first gate is in the second position, user access to a volume of the mobile robot station is provided such that a user can insert and remove items to and from a container carried by the mobile robot within the mobile robot station.

10. The mobile robot receiving system of claim 9, wherein, when the first gate is in the first position, user access to the volume of the mobile robot station is blocked such that the user cannot insert and remove items to and from the container carried by the mobile robot within the mobile robot station.

11. The mobile robot receiving system of claim 2, wherein: the first gate comprises a first cover portion configured to selectively allow and block access to a container carried by a mobile robot when the mobile robot is in the mobile robot station; and the second gate comprises a second cover portion configured to selectively reveal and block the exit of the mobile robot station.

12. The mobile robot receiving system of claim 11, wherein the mobile robot station is configured to occupy one of three states: a first state in which the mobile robot can move through the entrance into the mobile robot station; a second state in which the first cover portion to the mobile robot station has been pivoted about an axis to block the entrance and to confine the mobile robot within the mobile robot station; and a third state in which the second cover portion has been pivoted about the axis allowing user access to remove the mobile robot from the mobile robot station.

13. The mobile robot receiving system of claim 1, further comprising: a bot blocker disposed in cooperation with a pathway, mobile robots moving along the rail structure, the bot blocker movable between a blocking position, limiting movement of a mobile robot into or out of the mobile robot station, and a non-blocking position; and a roller on the first gate, the roller moving the bot blocker from the blocking position to the non-blocking position when the first gate moves from the second position to the first position.

14. The mobile robot receiving system of claim 1, further comprising: a bot blocker disposed in cooperation with a pathway, mobile robots moving along the rail structure, the block blocker movable between a blocking position, limiting movement of a mobile robot into or out of the mobile robot station, and a non-blocking position; and a support surface for a mobile robot comprising a projecting portion, the projecting portion configured for mounting to the mobile robot station and causing the bot blocker to move from a blocking position to a non-blocking position when mounting.

15. The mobile robot receiving system of claim 1, further comprising: an access port in the mobile robot station; and an access port cover movable between an open position, in which the access port is uncovered, and a closed position, in which the access port is covered, the first gate movable to the first position only when the access port cover is in the closed position.

16. A method of receiving a mobile robot comprising: moving a mobile robot along a pathway or a deck toward a mobile robot station proximate an edge of the pathway or deck; moving and receiving the mobile robot through a first gate at an entrance of the mobile robot station and accessible to the mobile robot moving along the pathway or deck, the first gate movable between a first position and a second position, wherein the mobile robot can move into or out of the mobile robot station via the entrance when in the first position, wherein the mobile robot is blocked from moving into or out of the mobile robot station via the entrance when in the second position.

17. The method of claim 16, further comprising: moving the mobile robot through a second gate at an exit of the mobile robot station, the second gate movable between a third position and a fourth position, wherein the mobile robot can be moved into or out of the mobile robot station via the exit when in the third position, and wherein the mobile robot cannot be moved into or out of the mobile robot station via the exit when in the fourth position.

18. The method of claim 17, further comprising: blocking the first gate from moving to the first position when the second gate is in the third position; and blocking the second gate from moving to the third position when the first gate is in the first position.

19. The method of claim 16, further comprising: when the first gate is in the second position, providing user access to a volume of the mobile robot station such that a user can insert and remove items to and from a container carried by the mobile robot within the mobile robot station.

20. The method of claim 19, further comprising: when the first gate is in the first position, blocking user access to the volume of the mobile robot station such that a user cannot insert and remove items to and from the container carried by the mobile robot within the mobile robot station.

21. The method of claim 17, further comprising: deactivating power to the mobile robot after the mobile robot has been received in the mobile robot station.

22. The method of claim 21, further comprising: docking a maintenance cart to the mobile robot station adjacent the second gate; andmoving the deactivated mobile robot through the second gate in the third position onto the maintenance cart.

23. A method of receiving a mobile robot comprising: transporting a deactivated mobile robot toward a mobile robot station disposed proximate an edge of a pathway or a deck; moving the mobile robot through an open external gate of the mobile robot station and onto a base of the mobile robot station, the external gate being movable between an open position and a closed position; closing the external gate and activating power to the mobile robot; and opening an internal gate of the mobile robot station, the internal gate being movable between an open position and a closed position, the internal gate providing the mobile robot with access to the pathway or deck to allow the mobile robot to move along the pathway or deck; wherein one of the external and internal gates is blocked from moving to an open position when the other of the external and internal gates is in an open position.