Automated carriers for use in inventory management systems

Abstract

A carrier for use in an inventory management system having multiple destination areas and a guide system includes a platform for receiving and transporting items to and from the destination areas, a plurality of motors, a first drive system, a second drive system, a transfer mechanism, and a clutch mechanism. The drive element of the first drive system is rotated by a first subset of one or more motors to move the carrier vertically. The drive element of the second drive system is rotated by a second subset of two or more motors to move the carrier horizontally. The transfer system is configured to transfer items to and extract items from the destination area, and the clutch mechanism is configured to engage and disengage the transfer mechanism with the second subset of motors, whereby the second drive system drives the movement of the carrier independently of the transfer mechanism.

Description

Technical Field

[0001] Embodiments of the present invention generally relate to automated vehicles configured to perform inventory management tasks in a warehouse, storage, and / or distribution environment. Background Art

[0002] Modern material handling systems used in mail order warehouses, supply chain distribution centers, and custom-order manufacturing facilities, for example, face significant challenges in responding to requests for inventory items. Initially, companies will typically invest in a level of automation that is at least adequate for the current needs. However, as inventory management systems scale to accommodate a greater number and variety of items, the operational costs and complexity of simultaneously completing packaging, storage, replenishment, and other desired inventory management tasks also increase.

[0003] Failure to effectively utilize resources such as space, equipment, and manpower in an inventory management facility can result in lower throughput, longer response times, and a growing backlog of uncompleted tasks. At one time, higher efficiencies could often be achieved by incrementally expanding the capacity of a facility's existing automation infrastructure, especially when the expansion followed a tight growth plan. However, sooner or later, a point of diminishing returns is encountered. That is, the realization of further gains in capacity and / or functionality ultimately becomes too costly compared to available alternatives, if such gains can be realized at all. When the point of diminishing returns is reached, facility operators may be forced to abandon the pre-existing material handling infrastructure and replace it with an entirely new automation platform. Summary of the invention

[0004] According to an embodiment of the present disclosure, the disadvantages and problems associated with conventional warehouse automation methods have been substantially reduced or eliminated by one or more carriers that can be configured to perform a variety of tasks related to inventory management operations. In an embodiment, each carrier is configured and operable to perform a first set of one or more inventory management tasks according to a first operating mode, and to interact cooperatively with any one of a plurality of functional attachment modules (FAMs) in order for it to perform one or more inventory management tasks according to an additional operating mode. Examples of tasks that each carrier is configured to perform using onboard resources include operating a transfer mechanism of the carrier to extract inventory items to a destination area of ​​a vertical array of storage areas, and / or extracting inventory items from the destination area. For such tasks, each carrier is configured to travel vertically along a guide system to bring the carrier to an appropriate destination area, and to travel horizontally on, for example, a substantially planar surface that extends between an array of storage areas and a remote location, such as a picking station, a packing station, or even a second vertical array of storage areas.

[0005] In an embodiment, one or more of the functional attachment modules are sized and arranged to facilitate their vertical and horizontal displacement with the aid of a carrier. In some embodiments, discrete groups of FAMs are constructed and operated to respectively perform different sets of inventory management tasks, so that even as the complexity of the inventory management system increases and new tasks must be accommodated, the carrier maintains its utility for the inventory management system. This modular approach enables the execution of different and / or those additional tasks simply by replacing and / or adding new types of FAMs that can perform additional inventory management tasks. Thus, challenges such as growing inventory differentials (e.g., higher SKU counts), rapidly increasing order picking volumes, and larger throughput requirements can be easily and simply addressed in a scalable manner.

[0006] In one embodiment, a vehicle configured to perform inventory management tasks includes a vehicle configured to perform inventory management tasks in an inventory management handling system having multiple destination areas and a guide system, the vehicle including: a platform sized and arranged to receive items to be transferred to or received from one of the destination areas; a plurality of motors; a first drive system having a first plurality of drive elements configured to engage the guide system through operation of a first subset of the plurality of motors to move the vehicle along a vertical section extending between a support surface below the vehicle and one of the destination areas; a second drive system having a first plurality of drive elements configured to engage the underlying support surface and drive movement of the vehicle in a non-vertical direction through operation of a second subset of the plurality of motors; a transfer mechanism configured to perform at least one of the operations of transferring items from the platform to or extracting items from one of the multiple destination areas; and a clutch mechanism configured to engage and disengage the transfer mechanism with a second subset of the motors, whereby the second drive system drives movement of the vehicle independently of the transfer mechanism.

[0007] In some embodiments, a first subset of one or more motors includes a single motor configured to rotate the first plurality of drive elements of a first drive system. In one embodiment, a second subset of motors includes a plurality of motors, wherein a first motor of the second subset drives rotation of a first drive element of a second drive system, and a second motor of the second subset drives rotation of a second drive element of the second drive system.

[0008] In some embodiments, the first plurality of drive elements of the first drive system comprises a plurality of gears sized and arranged to interact with complementary teeth of the guide system to control the position of the vehicle along the guide system. In this embodiment, the first drive system may comprise a pair of drive axles, wherein the driven gears are fixed to the drive axles so that the gears are driven synchronously to drive the vehicle along the guide system.

[0009] In some embodiments, the second drive system includes a first drive element driven by a first motor of the second subset to rotate about a first rotational axis, and a drive element driven by a second motor of the second subset to rotate about a second rotational axis, wherein each of the first and second drive elements is sized and arranged to engage a corresponding portion of an underlying support surface to effect movement of the carrier thereon. In one such embodiment, the clutch mechanism includes: a first pivotable carrier movable between a first angular orientation relative to the platform and a second angular orientation relative to the platform, wherein the first drive element is rotatably coupled to the first pivotable carrier for angular movement therewith; and a second pivotable carrier movable between the first angular orientation and the second angular orientation, wherein the second drive element is coupled to the second pivotable carrier for angular movement therewith. The first and second rotational axes are coaxial, and the first and second pivotable carriers have a common angular orientation.

[0010] Optionally, the second drive system further comprises a first driven element rotatably coupled to the first pivotable carrier and a first endless loop element for transferring rotational power to the first driven element; and a second driven element rotatably coupled to the second pivotable carrier and a second endless loop element for transferring rotational power to the second driven element. Each of the first endless loop element and the second endless loop element may comprise a belt. In this embodiment, the second drive system further comprises a first pulley, the first pulley and the first drive element being driven by a first motor of a second subset, wherein the first pulley is sized and arranged to engage the first endless loop element to thereby drive the first driven element; and a second pulley, the second pulley and the drive element being driven by a second motor of a second subset of motors, such that the pulley is sized and arranged to engage the second endless loop element to thereby drive the second driven element.

[0011] In the previous embodiment, the clutch mechanism may further include a third driven element, which is rotatably connected to the first driven element and coaxial therewith, and the third driven element is sized and arranged to drivingly engage the first portion of the transfer mechanism and thereby transfer power from the first motor of the second subset when the first pivotable carrier is in the first angular orientation; and a fourth driven element, which is rotatably connected to the second driven element and coaxial therewith, and the fourth driven element is sized and arranged to drivingly engage the second portion of the transfer mechanism and thereby transfer power from the second motor of the second subset when the second pivotable carrier is in the first angular orientation.

[0012] In an embodiment, the second drive system further comprises a plurality of omnidirectional wheels sized and arranged to frictionally engage respective portions of the underlying surface to thereby support the vehicle. In one such embodiment, the second first drive system further comprises a plurality of drive axles, wherein at least one pair of said omnidirectional wheels is driven by at least one motor of the second subset of motors.

[0013] In any of the foregoing embodiments, the vehicle may further include an onboard controller for directing operation of the plurality of motors, the controller comprising a processor and a memory, the memory containing instructions executable by the processor to operate a second subset of motors to drive first and second drive elements of a second drive system to thereby displace the vehicle along a substantially horizontal path on a support surface. In one such embodiment, the memory contains instructions executable by the processor to operate the second subset of motors to align corresponding portions of the first drive system with corresponding portions of the guidance system, and / or to initiate driving engagement of corresponding portions of the first drive system with corresponding aligned portions of the guidance system and thereby cause the vehicle to be raised or lowered relative to the reference plane.

[0014] In the previous embodiment, the clutch mechanism can be configured to enable power to be transmitted from the second subset of motors to the transfer mechanism in response to the carrier being raised to a position above the reference plane. To this end, the memory further contains instructions executable by the processor to operate the motors of the second subset of one or more motors to cause the transfer mechanism to perform one of the following operations: transfer an item from the platform to a destination area adjacent to the carrier, or extract an item from the destination area to the platform. In this embodiment, the clutch mechanism is configured to disable actuation of the transfer mechanism in response to the carrier being lowered to a position below the reference plane.

[0015] Another embodiment of a vehicle operable in an inventory management system having multiple destination areas and a guidance system includes: a first motorized drive system configured to engage the guidance system to guide movement of the vehicle along a vertical segment; a second motorized drive system sized and arranged to maneuver the vehicle on a surface while the first drive system is not engaged with the guidance system; a clutch mechanism operative to engage and disengage transmission of power to and from a transfer mechanism, whereby each of the first drive system and the second drive system can operate independently of the transfer mechanism; and a transfer mechanism operative to transfer items between the vehicle and one of the multiple destination areas; wherein the first motorized drive system includes a first pair and a second pair of motor-driven rotating elements, each pair of rotating elements being configured to interact with the guidance system to control the position of the vehicle along the guidance system.

[0016] In the previous embodiment, each rotary drive element of the first and second pairs of rotary drive elements can be a gear having teeth that are sized and arranged to engage complementary teeth of the guide system as the vehicle changes elevation along the guide system. In one such embodiment, the first drive system further includes a pair of synchronous drive axles, wherein driven gears are fixed to the axles so that the gears are synchronously driven to drive the vehicle along the guide system. Optionally, the clutch mechanism is sized and arranged to disengage the transfer mechanism as the vehicle descends to a position beyond the reference plane, thereby disabling actuation of the transfer mechanism by the controller. In this embodiment, the clutch mechanism can be configured to engage with the transfer mechanism as the vehicle rises to a position above the reference plane, thereby enabling actuation of the transfer mechanism by the controller.

[0017] According to another embodiment, a carrier operable in an inventory management system includes: a first motor and a second motor; a first pair of omnidirectional rollers and a second pair of omnidirectional rollers, wherein the first omnidirectional rollers of each pair are sized and arranged to rotate about a first rotation axis, and wherein the second omnidirectional rollers of each pair are driven by the first motor or the second motor to rotate about a second rotation axis; a fifth roller, which is driven by the first motor or the second motor; and an actuator having an actuating surface, the actuating surface being configured to move from a first position to a second position to selectively push the fifth roller in a direction toward an underlying support surface; wherein a surface of each of the first and second pairs of omnidirectional rollers and a surface of the fifth roller are sized and arranged to contact the underlying support surface when the actuator is maintained in the first position, and wherein movement of the actuator to the second position causes a load to be transferred from one or more of the omnidirectional rollers to the fifth roller.

[0018] In some embodiments, the pair of motor driven omni-directional rollers is driven independently of the second pair of motor driven omni-directional rollers.

[0019] In some embodiments, the actuator is a first actuator, wherein the carrier further includes a sixth roller and a second actuator movable from a third position to a fourth position, and wherein movement of the first and second actuators into the second and fourth positions, respectively, causes a load to be transferred from one or more of the omnidirectional rollers to the fifth roller and the sixth roller.

[0020] In the previous embodiment, the carrier further comprises a platform and a transfer mechanism, the transfer mechanism being used to transfer the object from the platform to the target surface or to extract the object from the target surface. Optionally, the carrier of the previous embodiment may further comprise a clutch mechanism for engaging and disengaging the transfer mechanism.

[0021] Other and further embodiments of the invention are described below.

[0022] To facilitate understanding, the same reference numerals have been used where possible to represent the same elements common to the figures. The figures are not drawn to scale and may be simplified for clarity. Upon careful consideration, elements and features of one embodiment may be advantageously incorporated in other embodiments without further recitation. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order that the above-mentioned features of the present invention may be understood in detail, a more specific description of the present invention briefly summarized above may be made by reference to embodiments, some of which are shown in the accompanying drawings. However, it should be noted that the accompanying drawings only illustrate typical embodiments of the present invention and therefore should not be considered as limiting the scope of the present invention, because the present invention may admit of other equally effective embodiments.

[0024] Figure 1A is a perspective view depicting an inventory management system according to one or more embodiments of the present disclosure, the inventory management system comprising a plurality of automated guided vehicles, each of the plurality of automated guided vehicles being configurable to perform a subset of inventory management tasks supporting a parts picking process by interacting with one or more functional attachment modules;

[0025] Figure 1B is a perspective view depicting an inventory management system according to one or more embodiments of the present disclosure, the inventory management system comprising a plurality of automated guided vehicles, each of the plurality of automated guided vehicles being configurable to perform a first subset of inventory management tasks by interacting with functional attachment modules of a first group of functional attachment modules, and to perform a second subset of inventory management tasks by interacting with functional attachment modules of a second group of functional attachment modules;

[0026] Figure 1Cis a perspective view depicting an inventory management system according to one or more embodiments of the present disclosure, the inventory management system comprising a plurality of automated guided vehicles, each of the automated guided vehicles being configurable to perform a first, second, and / or third subset of inventory management tasks by interacting with one or more functional attachment modules of a first, second, or third group of functional attachment modules;

[0027] Figure 2A is a diagram illustrating an exemplary embodiment of the present disclosure and suitable for use in Figures 1A to 1C A perspective view of an automated guided vehicle used in any of the inventory management systems depicted in;

[0028] Figure 2B yes Figure 2A A top view of an exemplary automated guided vehicle depicted in FIG.

[0029] Figure 2C yes Figure 2A A bottom view of an exemplary automated guided vehicle depicted in FIG.

[0030] Figure 2D yes Figure 2A A front elevation view of an exemplary automated guided vehicle depicted in FIG.

[0031] Figure 2E yes Figure 2A A rear elevation view of an exemplary automated guided vehicle depicted in;

[0032] Figure 2F yes Figure 2A A side elevation view of an exemplary automated guided vehicle depicted in FIG.

[0033] Figure 2G is a top plan view depicting an automated guided vehicle in the process of extracting a container of inventory items from a storage area in a plurality of storage areas arranged in a vertical row according to one or more embodiments;

[0034] Figure 2H is a cross- Figure 2G A partial side elevation view showing actuation of the transfer mechanism, taken along line II-H in FIG.

[0035] Fig.2I yes Figure 2H to show more detail of an illustrative transfer mechanism that may be used to transfer items to and from a storage area;

[0036] Figure 3A It is cross Figure 2A The line IIIA-IIIA in the cross section is cut Figures 2A-2F A front elevation view of an exemplary automated guided vehicle;

[0037] Figure 3B yes Figures 2A-2F A bottom plan view of an exemplary automated guided vehicle of with its clutch mechanism partially disassembled to expose its internal structure;

[0038] Figure 4A It is cross Figure 2A The line IVA-IVA in the cross section is taken Figures 2A-2F A side elevation view of an exemplary automated guided vehicle of FIG.

[0039] Figure 4B According to one or more embodiments, Figure 2A The line IVA-IVB in the cross section is taken Figures 2A-2F A side elevation view of an exemplary automated guided vehicle of FIG. 1 with its clutch mechanism disengaged;

[0040] Figure 4C According to one or more embodiments, Figure 2A The line IVB-IVB in the cross section is cut Figures 2A-2F A side elevation view of an exemplary automated guided vehicle of FIG. 1 with its clutch mechanism engaged;

[0041] Figure 4D and 4E yes Figures 2A-2F A side elevation view of an exemplary automated guided vehicle of , with a lateral exterior cover omitted to reveal an optional actuator mechanism having a selectable position in a first position ( Figure 4D ) and the second position ( Figure 4E ) a force applying member moving between;

[0042] Figure 4F yes Figure 4D and 4E an enlarged view of the actuator mechanism depicted in , the force applying member being shown in a first non-force applying position;

[0043] Figure 4G yes Figures 4D to 4F an enlarged view of the actuator mechanism depicted in , with its force applying component shown in a second force applying position;

[0044] Figure 5A is a front perspective view depicting the use of an automated guided vehicle in conjunction with a first group of functional accessory modules according to one or more embodiments;

[0045] Figure 5B is a perspective view depicting a pre-docking alignment of an automated guided vehicle with a first illustrative substrate, which may be implemented as a component of a functional attachment module, implemented as a Figures 1A to 1Cand any of the functional accessory modules shown in 5A, or implemented as a separate functional accessory module that acts as an adapter between the carrier and at least one of those other types of functional modules;

[0046] Figure 5C is a perspective view depicting a post-docking alignment of an automated guided vehicle with a second alternative substrate, which may be implemented as a component of a functional attachment module, implemented as Figures 1A to 1C and any of the functional accessory modules shown in 5A, or implemented as a separate functional accessory module that acts as an adapter between the carrier and at least one of those other types of functional modules;

[0047] Figure 5D It is an automated guided vehicle and e.g. Figure 5C A rear elevation view of a substrate docking depicted in , wherein respective surfaces of each of the substrate and carrier contact an underlying support surface at a plurality of points;

[0048] Figure 5E After the first drive system of the carrier has been actuated to lift the substrate docked therewith so that no surface of the substrate contacts the underlying support surface Figure 5D A rear elevation view of the docked automated guided vehicle;

[0049] Fig. 6A is a perspective view depicting a post-docking alignment of an automated guided vehicle with a third alternative substrate according to respective embodiments, the substrate being implemented as a component of a functional attachment module, as Figures 1A to 1C and one or more of the functional accessory modules shown in 5A, or implemented as a separate functional accessory module that acts as an adapter between the carrier and at least one or more of those other types of functional modules;

[0050] Figure 6B After the first drive system of the carrier has been actuated to lift the substrate docked therewith so that none of its surfaces are in contact with the underlying support surface Fig. 6A A rear elevation view of the docked automated guided vehicle;

[0051] Figure 6C It is based on the description Figures 5A to 6B A perspective view of an inventory management system for placement and use of multiple functional accessory modules constructed in any of the embodiments shown in the embodiment;

[0052] Fig. 7A is a perspective view depicting a pre-docking alignment of an automated guided vehicle with a first functional accessory module, the first functional accessory module being sized and arranged to function as a carrier and Figures 1A to 1C adapters between at least one or more of the other types of functional modules shown in;

[0053] Figure 7B It is a depiction Fig. 7A A perspective view of a post-docking alignment between the semi-autonomous vehicle and the first functional attachment module;

[0054] Figure 7C yes Figure 7B a rear elevation view of the docked automated guided vehicle and first functional accessory module, wherein respective surfaces of each of the vehicle and the first functional accessory module are in contact with an underlying support surface at a plurality of points;

[0055] Fig.7D After the first drive system of the carrier has been actuated to lift the first functional accessory module so that no surface of the first functional accessory module contacts the underlying support surface Figure 7B A rear elevation view of the docked automated guided vehicle and the first functional accessory module;

[0056] Fig. 8A is a diagram illustrating a method according to one or more embodiments Fig.7D a partial elevation view of a docked semi-automatic guided vehicle and a first functional accessory module aligned prior to docking with a second functional accessory module, the second functional accessory module being implemented as a multi-layer storage rack having a surface sized and arranged to support the rack on an underlying support surface;

[0057] Figure 8B is depicted after the first drive system of the carrier has been actuated to further lift the first functional accessory module and also lift the second functional accessory module such that no surface of either the first or second functional accessory module is in contact with the underlying support surface Fig.7D and 8A A partial front view of the docked automated guided vehicle and the first functional accessory module aligned with the second functional accessory module after docking;

[0058] Figure 8C is depicted in Figure 8B A full front view of the relative positions of the automated guided vehicle, the first functional accessory module, and the second functional accessory module after the second functional accessory module is lifted and docked in the manner shown in FIG.

[0059] Fig. 9 is a partial perspective view depicting elements of an inventory management system including respective groups of first and second accessory modules with which an automated guided vehicle is adapted to cooperate to perform a corresponding subset of inventory management tasks, and a group of third functional accessory modules with which the automated guided vehicle is adapted to cooperate to perform yet another subset of inventory management tasks, according to one or more embodiments;

[0060] Fig. 10A and 10Bis a front view depicting a docking alignment between an automated guided vehicle and one of the functional attachment modules from a third group, but prior to activating a first drive system of the automated guided vehicle, according to some embodiments;

[0061] Fig. 10C According to one or more embodiments, Fig. 10A and depicting the facing alignment of a rotational element of the first drive system with a corresponding portion of a guide system of a functional accessory module from a third group of accessory modules;

[0062] Fig. 10D According to one or more embodiments, Fig. 10A and 10C an enlarged partial front view after actuating a corresponding rotary element of a first drive system of the carrier with a corresponding counter-part of a guide system of the functional accessory module for lifting the functional accessory module in a first direction, from the same viewing angle;

[0063] Fig. 10E According to one or more embodiments, Fig. 10B A front view after actuating the rotary element of the first drive system in the first direction with a corresponding counter-part of the guide system of the functional accessory module for lifting the functional accessory module, from the same viewing angle;

[0064] Fig.10F According to one or more embodiments, Fig. 10B and 10E A front view from the same perspective after actuating a corresponding rotary element of a first drive system of the carrier in a second direction with a corresponding opposing portion of a guide system of the functional accessory module for placing the functional accessory module on an underlying support surface and subsequently lifting the carrier within the functional accessory module as shown;

[0065] Fig.11A is a diagram depicting a method of, for example, Figures 10A to 10F A rear perspective view of an exemplary module depicted in Figure 1 and other functional attachment modules deployed to a mobile rack structure sized and arranged to supply items such as fast-moving merchandise in an item-to-picker inventory management system;

[0066] Fig. 11B According to one or more embodiments, just before the functional accessory module is docked with the mobile rack structure Fig. 11B A side elevation view of an illustrative embodiment of;

[0067] Fig. 11CAfter the functional accessory module is docked with the flow rack structure and the carrier within the functional accessory module is raised into position for transferring items from the carrier to the target surface of the flow rack according to one or more embodiments. Fig.11A and 11B A side elevation view of an illustrative embodiment of;

[0068] Fig.11D According to one or more embodiments Figures 11A to 11C A front perspective view of an illustrative embodiment of the invention depicting a carrier within a functional accessory module raised to Fig. 11C In the location shown in;

[0069] Fig.11E According to one or more embodiments Figures 11A to 11D A top plan view of an illustrative embodiment of the invention depicting a carrier within a functional accessory module raised to Fig. 11C and 11D In the location shown in;

[0070] Fig.11F According to one or more embodiments of the present disclosure, the container is Fig.11E During the transfer of the surface of the mobile rack structure to the platform of the raised carrier (as part of the dynamic redistribution of inventory) Figures 11A to 11E An enlarged top plan view of an illustrative embodiment of;

[0071] Fig.11G is a diagram depicting a method according to one or more embodiments consistent with the present disclosure. Figures 11A to 11F A top plan view of an illustrative embodiment of depicting items being transferred from one carrier to another using a FAM as part of dynamic allocation of inventory;

[0072] Fig.11H is a rear elevation view depicting one or more inventory management tasks performed by a vehicle and at least one FAM to achieve dynamic allocation of inventory according to one or more embodiments;

[0073] Fig.11I is a rear elevation view showing a carrier within a functional accessory module raised to a position suitable for item transfer after the module has been docked with a flow rack according to one or more embodiments;

[0074] Fig.12 is a diagram that can be formed according to one or more embodiments Figure 1C A partial perspective view of a portion of an inventory management system that utilizes automated guided vehicles to transfer containers of inventory items to and from a picking area and a plurality of storage locations;

[0075] Fig.13Ais a diagram illustrating a plurality of automated guided vehicles operating as Fig.12 A front elevation view of a portion of an inventory management system that performs various item replenishment and / or item retrieval tasks;

[0076] Fig. 13B is a diagram illustrating a plurality of automated guided vehicles operating as Fig.12 A side elevation view of a portion of an inventory management system performing various item replenishment and / or item retrieval tasks;

[0077] Fig. 13C is a diagram illustrating a plurality of automated guided vehicles operating as Fig.12 A top plan view of a portion of an inventory management system that performs various item replenishment and / or item retrieval tasks;

[0078] Fig.13D According to one or more embodiments Fig. 13B an enlarged side elevation view of a structure of which depicts an exemplary vertical support and guide system;

[0079] Fig.13E is an enlarged elevation view depicting a segment of a guide system for use in a rack structure according to one or more embodiments;

[0080] Fig.14A is a schematic block diagram depicting the distribution of FAM-assisted inventory management tasks among multiple vehicles by a controller according to one or more embodiments;

[0081] Fig. 14B is a block diagram depicting a plurality of guidance vehicle subsystems according to one or more embodiments;

[0082] Fig. 14C is a schematic block diagram of a controller that may be used to coordinate the assignment and execution of inventory management task activities by multiple vehicles and FAMs according to one or more embodiments consistent with the present disclosure;

[0083] Fig.15 is a flow chart depicting a process by which inventory management tasks may be assigned to one or more vehicles and FAMs according to one or more embodiments;

[0084] Fig.16 is a flow chart depicting a process by which inventory items may be dynamically allocated among various storage areas over a series of consecutive inventory management intervals in accordance with one or more embodiments; and

[0085] Fig.17is a flow chart depicting a process by which an automated guided vehicle performs inventory management tasks using only the vehicle's onboard resources and capabilities according to a first operating mode and supplementing the vehicle's resources using additional resources and capabilities of one or more FAMs according to a second operating mode.

[0086] Although the systems and methods are described herein with the aid of examples for several embodiments and illustrative figures, those skilled in the art will recognize that the systems and methods for performing the corresponding subset of inventory management tasks using the corresponding functional accessory modules are not limited to the described embodiments or figures. It should be understood that the drawings and their detailed description are not intended to limit the embodiments to the specific forms disclosed. In fact, it is intended to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of the systems and methods for performing the corresponding subset of inventory management tasks using the corresponding functional accessory modules as defined by the appended claims. Any headings used herein are for organizational purposes only and are not intended to limit the scope of the specification or claims. As used herein, the word "may" is used in a permissive sense (i.e., meaning possible) rather than a mandatory sense (i.e., meaning must). Similarly, the word "including" means including but not limited to. DETAILED DESCRIPTION

[0087] Various embodiments of a method and apparatus for performing inventory management tasks in an inventory management system are described. In the following detailed description, numerous specific details are set forth to provide a thorough understanding of the claimed subject matter. However, one skilled in the art will appreciate that the claimed subject matter can be practiced without these specific details. In other instances, methods, apparatuses, or systems that are otherwise known to one of ordinary skill in the art are not described in detail in order to avoid obscuring the claimed subject matter.

[0088] Some parts of the following detailed description are presented in terms of algorithms or symbolic representations of operations on binary digital signals stored in the memory of a specific device or a special computing device or platform. In the context of this particular specification, the term specific device, etc. may include a general-purpose computer that is programmed to perform specific functions according to instructions from program software. Algorithmic descriptions or symbolic representations are examples of techniques used by a general technician in signal processing or related technical fields to convey the gist of their work to other technicians in the field. Algorithms are here and generally considered to be a self-consistent sequence of operations or similar signal processing that produces a desired result. In this context, operations or processing involve physical manipulation of physical quantities. Typically, but not necessarily, such quantities can take the form of electrical or magnetic signals that can be stored, transmitted, combined, compared or otherwise manipulated. Mainly for reasons of common use, it has sometimes proven to be convenient to refer to such signals as bits, data, values, elements, symbols, characters, items, numbers, numbers, etc. However, it should be understood that all of these or similar terms should be associated with appropriate physical quantities and are only convenient labels.

[0089] Unless explicitly stated otherwise, as will be apparent from the following discussion, it should be understood that discussions throughout this specification utilizing terms such as "processing," "computing," "calculating," "determining," etc. refer to the actions or processes of a specific device such as a special-purpose computer or similar special-purpose electronic computing device. Thus, in the context of this specification, a special-purpose computer or similar special-purpose electronic computing device is capable of manipulating or transforming signals, which are typically represented as physical electronic or magnetic quantities within a memory, register, or other information storage device, transmission device, or display device of the special-purpose computer or similar special-purpose electronic computing device.

[0090] Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

[0091] Embodiments consistent with the present disclosure include one or more automated guided vehicles that are configurable to perform a variety of tasks associated with inventory management operations. In order to maintain a high degree of modularity, vehicles constructed in accordance with some embodiments of the present disclosure are configured and operable to perform a first subset of one or more inventory management tasks, and to interact with any of a plurality of interchangeable functional attachment modules (FAMs) in order to perform another subset of one or more inventory management tasks. In an embodiment, a subset of FAMs may be shifted vertically and horizontally so that they may be moved to different locations within an inventory management facility as needed. The facility may be, for example, a distribution center where inventory items are stored for subsequent shipment to retail store locations, and / or a fulfillment center where inventory items are shipped directly to retail customers.

[0092] Each FAM of a group of FAM has at least one function, capability or physical attribute not in the carrier and the FAM of different groups.In an embodiment, carrier and FAM cooperate with each other to perform various tasks according to the mode of each carrier operation and the specific FAM paired with the carrier at a given time.By replacing a FAM or FAM set with one or more other FAMs, any one in the carrier can be easily configured to perform the replacement or extra set of inventory management tasks.Therefore, even with the complexity increase of the system to realize further inventory differentiation (for example, adapting to higher SKU count), higher order picking volume and / or greater throughput requirements, the carrier also keeps its utility in the inventory management system.

[0093] As will be described in more detail later, an association of indeterminate duration is formed between a vehicle and one or more of the FAMs to enable execution of a second subset of one or more inventory management tasks. In some cases, all functionality required to complete the second subset of inventory management tasks is obtained through the combination of the vehicle and a single or first FAM. In an embodiment, the association formed between the first FAM and the vehicle is achieved through direct engagement of one or more components of the vehicle with one or more components of the FAM. In other cases, execution of the second subset of one or more inventory management tasks further requires the use of an additional or second FAM. In an embodiment, the second FAM performs the function of an adapter between the vehicle and the first FAM. According to an embodiment, once the assigned subset of inventory management tasks is completed and / or some other task(s) require the use of any and all of these components, the association between any and all vehicles and any associated FAMs is terminated.

[0094] Order picking systems, such as mail order or e-commerce warehouses, supply chain distribution centers, cross-dock facilities, custom-made manufacturing facilities, or any other type of inventory system, typically differ from one another in terms of: (i) who and / or what picks items; (ii) who and / or what moves within the picking zones; (iii) whether the different picking zones are connected by conveyors; and (iv) what picking strategy is being applied. Available picking systems include picker to part, pick to bin, pick and sort, part to picker, and fully automated picking. The level of automation required for implementation increases as the order picking system moves from picker to part to fully automated picking systems.

[0095] The most basic order picking system in use today is the picker-to-parts system. Here, human pickers walk (or drive) along aisles and manually pick items from storage locations. In low-level picking systems, items are stored in storage racks or bins that can be easily reached by the pickers. In advanced picking systems, pickers use lift trucks or cranes to reach items stored in higher storage racks. Either type of picker-to-parts system is easy to implement, modify, and scale, but their use is generally limited to applications where both the pick volume and inventory item (e.g., SKU) counts are low. This limitation is due to the sharp drop in productivity as travel time increases.

[0096] A zone picking system is similar to a picker-to-parts system in that the picking activities are all performed by human pickers. However, the area in which the workers perform the picking is divided into discrete zones. These picking zones are connected by conveyor belts. Orders are picked sequentially by zone and then they are sorted according to the destination. Each customer order usually corresponds to a pick box, and once all the required items have been picked in the current zone, the pick box is transferred to the next zone. An effective pick-to-bin system is one in which the workload is balanced between the various picking zones. Pick-to-bin systems are often used in situations where there are many small items in stock but the orders themselves are usually for a small number of items.

[0097] Figure 1A is a perspective view depicting an inventory management system 10 including a plurality of autonomous or automated guided vehicles 12. According to one or more embodiments of the present disclosure, each vehicle 12 may be configured to perform a subset of inventory management tasks that support a parts picking process by interacting with one or more functional attachment modules (FAMs). Figure 1A In the illustrative embodiment of , the inventory management system 10 implements a "picker to part" approach or alternatively a zone approach. In either case, inventory items (not shown) are stored in and retrieved from storage racks, indicated generally at 14. The storage racks 14 define rows and columns of storage units sized and arranged to receive bins 16 containing items. The bins are at a sufficiently low height that they can be easily reached by human pickers P1.

[0098] As an advancement over picker-to-part systems or picker-to-bin approaches that have utilized low-level storage racks 14 and bins 16, Figure 1A The embodiment of the inventory management system 10 shown in FIG. 1 may be implemented simply by adding a carrier 12 and a plurality of FAMs 18 that collectively form a first group of FAMs. Each FAM 18 of the first group includes a base 20, a vertical support or handle 22 extending in an upward direction from the base 20, and a plurality of item storage units 24 mounted on the handle 22. Figure 1A In an embodiment of the present invention, a user terminal with a touch screen display 26 is also mounted on the handle 26 to accommodate the presentation of various instructions to the picker and to allow for confirmatory acknowledgement to be entered in accordance with one or more inventory management tasks to be performed by each FAM 18. In some embodiments, the same picker who transfers an item from one of the shelves 14 to one of the FAMs 18 follows the FAM to a packing station such as station S1 or S2. At the packing station, the item is transferred into a carrier for shipment.

[0099] To implement a zone picking scheme utilizing a carrier 12 and a FAM 18, items are removed from inventory and placed in one or more storage cells 24 of a selected FAM 18 by a picker operating in a first storage area. The selected FAM 18 then travels to a second storage area (not shown) without the picker accompanying it. At the second storage area, another picker removes additional items from inventory and transfers the items to the one or more storage cells of the selected FAM 18. The FAM 18 may thus be configured to perform the function of a conveyor belt connecting different picking zones.

[0100] The FAM 18 is also used in conjunction with the carrier 12 to perform inventory management tasks according to a pick and sort method, also known as a wave picking system. A wave picking arrangement consists of one or more picking areas and one or more sorting areas. Inventory items associated with multiple customer orders are picked in batches. After picking, the batches of items can be placed in a corresponding FAM 18 instead of a conveyor belt so that the FAM 18 takes the picked items to a sorting area (not shown). Pick and sort systems typically operate in the form of picking waves, where all orders are sorted before releasing the next wave.

[0101] Now go to Figure 1B , showing a perspective view of an inventory management system 30 according to one or more embodiments, the inventory management system is incorporated for illustrative example purposes only. Figure 1A Specifically, the inventory management system 30 retains the pre-existing elements of the inventory management system 10 previously included in Figure 1A and optionally further incorporating a previously acquired FAM 18 of a first group of storage shelves 14, bins 16, and FAMs. Figure 1B The inventory management system 30 of the embodiment further includes a plurality of additional FAMs, such as a FAM 40 of a second group of FAMs and a FAM 50 of a third group of FAMs. As will be described in greater detail later, the vehicle 12 is configured to interact with the FAMs 40 and 50, respectively, to cooperatively perform a subset of inventory management tasks that is different from the inventory management tasks performed through interaction with one of the FAMs 18.

[0102] In the process of picking items for order fulfillment, a distinction is made between two types of items, namely, fast-moving and slow-moving. Fast-moving items are those inventory units that are frequently needed and / or required in larger quantities. On the other hand, slow-moving items are those inventory items that are rarely needed or required in smaller quantities. It is possible for items to move from one of these two categories to the other. The movement may be bidirectional, for example due to the cyclical nature of consumer demand depending on the time of year (e.g., back-to-school season, seasonal items, holiday promotions, etc.). In some cases, a newly introduced product in the inventory may experience a high demand growth rate causing the product to enter and remain in the fast-moving category for an extended period of time. Conversely, a shift into the slow-moving category may indicate a permanent decline in the popularity of a mature product. For example, Figure 1B As illustrated by the illustrative inventory management system 30 of , the ability to deploy additional and / or different types of FAMs as needed allows a warehouse or distribution center facility operator to dynamically adapt to short-term and long-term shifts in demand for inventory items.

[0103] exist Figure 1B In the embodiment depicted in , the inventory management system 30 includes a plurality of multi-layer storage racks, indicated generally at 60. The storage racks 60 define a plurality of storage surfaces, indicated generally at 62, 64, and 66. Each of the FAMs 40 includes a base 42, which is sized and arranged to fit under any one of the racks 60 and is placed there by one of the carriers 12 docked therewith. In a manner to be described later, each carrier 12 can be used to lift the FAM 40 docked therewith and also lift the rack 60 with the FAM 40 positioned below. The carrier 12 paired with the FAM 40 can further be used to transport the lifted rack 60, for example, from one of the positions occupied by racks 60a, 60b, or 60c to one of the positions adjacent to the picking area P currently occupied by racks 60d, 60e, and 60f.

[0104] Continue to view Figure 1B, it will be seen that carrier 12a is depicted as docking with shelf 60f, where they can be accessed by the picker. For example, other shelves 60 such as shelves 60a, 60b and 60c are shown as having been stored in a storage area by performing appropriate inventory management tasks by carrier 12 and FAM 40, and the storage area includes a symmetrical arrangement of rows separated by aisles through which the carrier can pass. Arranging the shelves 60 with inventory items stored on their storage surfaces in this compact manner allows any one of the shelves 60 to be transferred to picking or alternatively to a sorting area (not shown) by associating one of the carriers such as carrier 12a with one of the FAM40 when fulfilling the demand for the items (such as in the order fulfillment process). In some embodiments, the rows of shelves such as shelves 60a, 60b and 60c act as buffer areas, and the inventory flow containing shelves that is smoothly and periodically refreshed is extracted from the buffer area and provided to one or more nearby picking and / or sorting areas. The number of shelves in this buffer area can increase or decrease according to the fluctuation of the order volume. Alternatively or in addition, additional shelves 60 may be arranged in one or more rows separated by aisles at locations further away from the picking and / or sorting areas, depending on the relative frequency of demand for inventory items maintained in such shelves.

[0105] As mentioned earlier, Figure 1B The illustrative inventory management system 30 depicted in further includes a third group of FAMs, wherein the third group of FAMs is generally indicated at 50; and a plurality of multi-layer storage racks generally indicated at 60. The storage racks 60 define a plurality of storage surfaces generally indicated at 62, 64, and 66. Each of the FAMs 40 includes a base 42 that is sized and arranged to fit under any one of the racks 60 and is placed there by one of the carriers 12 docked therewith. In a manner that will be described later, each carrier 12 can be used to lift the FAM 40 docked therewith and also lift the rack 60 positioned below the FAM 40. The carrier 12 paired with the FAM 40 can further be used to transport the lifted rack 60, for example, from one of the positions occupied by racks 60a, 60b, or 60c to one of the positions adjacent to the picking area P currently occupied by racks 60d, 60e, and 60f.

[0106] exist Figure 1B, the inventory management system 30 further includes a multi-layered flow rack structure, indicated generally at 70. For example, the flow rack 70 can be used to accommodate inventory items that are removed from inventory in larger quantities than the items stored in the shelves 60. In one embodiment, one or more layers of the flow rack structure 70, such as the upper layers 72 and 74, are configured as conveyors that are selectively actuated as needed to move inventory items forward to a location proximate to a picking and / or sorting station operator. As previously described, the illustrative inventory management system 30 further includes a third group of FAMs, wherein the third group of FAMs is indicated generally at 50.

[0107] In an embodiment and as will be described in greater detail later, a carrier 12, such as carrier 12b, is sized and arranged to dock with, lift, and transport any of the FAMs 50 for the purpose of replenishing a mobile rack structure 70. To this end, each FAM 50 defines an internal row that is sized and arranged to enable any of the carriers 12 to move vertically (upward or downward) within the FAM 50 when in the position shown as occupied by carrier 12b. This movement enables the carrier 12 to climb to a level within any FAM 50 that is aligned within one of the storage levels of the rack structure 70. Once such alignment is achieved, each carrier can be used to perform inventory transfer tasks, wherein containers or boxes of items, or in other embodiments, pallets of items, are transferred from the surface of the carrier 12 to a storage level of the rack structure 70 that is aligned with the carrier surface. Figure 1B , carrier 12B is shown in the process of transporting a first of FAMs 50 along a path parallel to rack structure 70. Another of FAMs 50 is shown in interlocking alignment with rack structure 70, wherein the carrier is ready to begin the process of lifting and transferring boxes 76 into mobile rack structure 70.

[0108] Now go to Figure 1C , showing a perspective view of an inventory management system 100 according to one or more embodiments, the inventory management system being incorporated with reference to the accompanying drawings for purposes of illustrative example only. Figure 1B Specifically, the inventory management system 100 retains the pre-existing elements of the inventory management system 30 previously included in Figure 1A, and optionally further incorporates FAMs 40 and 50, portable storage racks 60, and mobile rack structures 70. Some of the carriers 12 are utilized as part of a storage and retrieval assembly or SAR that also includes an array of destination areas or storage locations 110. The storage locations 110 are arranged in rows. As will be described in more detail later, the SAR of the system 100 includes a guidance system, such as a track (not shown), to vertically guide the carrier in order to reach a given storage location.

[0109] One of the inventory management tasks assigned to a vehicle 12 operating as part of a SAR is to extract an item from a storage location 110. This task can be viewed as a series of subtasks that include exiting the vehicle's current or starting location, traversing the path taken by the vehicle between the starting location and an intermediate destination to an entry point in an array of adjacent storage locations, and aligning the vehicle 12 with the entry point at the intermediate destination. As another subtask of the extraction task, the aligned vehicle enters the array and maintains its alignment until it reaches the column where the vehicle is located, is operated to climb according to yet another subtask until it reaches a target storage area in the storage area 110. As an additional subtask of the extraction process, the vehicle's transfer mechanism is operated to extract the item, descends within the column until the vehicle rests on a support surface, and then exits the array of storage locations. As the final subtask of the extraction operation, the vehicle 12 continues along the path to the output station 120, where an operator can extract the item from the vehicle.

[0110] In one or more embodiments, the carrier may perform a power replenishment task and then return any remaining items that were not retrieved by the operator to the storage area. In this regard, the carrier may simply re-perform the series of subtasks to retrieve the item, except that instead of operating the transfer mechanism of the carrier to retrieve the item at the target storage location, the transfer mechanism is instead used to transfer the item from the platform of the carrier to the target storage location. If there is still enough power after the transfer, the carrier can proceed to another storage area to obtain the next item to be retrieved. In this way, the system 100 includes a plurality of individually controlled carriers, such as carrier 12, which move up and down along a track within any of a plurality of columns to retrieve items from various storage areas and provide the items to the operator, then return any remaining items and then retrieve another item.

[0111] For ease of illustration, the carrier 12 cooperating as part of the SAR has been described as delivering items to and / or retrieving items from the storage area 110. The items may be configured so that individual items are stored at a storage location. However, in a typical operating environment, the items are stored in or on a storage mechanism such as a container or a platform. For example, the items may be stored in a container referred to as a tote. The tote may be similar to a carton or box without a lid so that an operator can easily reach into the tote at a picking station to retrieve the items. Although the system of the present invention is described as using a tote, it should be understood that any of a variety of storage mechanisms may be used, such as a pallet or similar platform.

[0112] Figure 1C The storage location 110 of the illustrative system 100 depicted in FIG. 1 can be any of a variety of configurations. For example, the simplest configuration is a shelf configuration for supporting items or containers containing items. Similarly, the storage location 100 can include one or more brackets that cooperate with the storage mechanism to support the storage mechanism in the storage location. For example, in this example, the storage location includes a bracket similar to a shelf for supporting one of the tote boxes, such as Figure 1C Described in.

[0113] A subset of carriers 12 may thus be configured to perform a subset of inventory management tasks associated with the storage and retrieval of totes T containing items from storage area 110 and the delivery of totes T to a delivery station 120 where an operator may retrieve one or more items from the totes. Although previously described as a single carrier performing all subtasks including a retrieval task, it is alternatively possible to distribute the subtasks of a given task among multiple carriers 12 in accordance with one or more embodiments. For example, a first carrier exiting the array of storage area 110 may transfer its retrieved items to a second carrier, which in turn completes the retrieval task by delivering the items to a delivery station 120. After the operator retrieves the items, the same carrier or another carrier 12 propels the tote T out of the delivery station 120 and returns the tote to the same or a different storage location in the storage locations 110.

[0114] in accordance with Figures 1A to 1C With the above high-level description, it should be appreciated that the vehicle 12 may be operated in a certain operating mode to cooperate cooperatively with one or more FAMs to perform various sets of inventory management tasks, and in another operating mode to perform other inventory management tasks that do not require association with any of the FAMs, such as FAMs 30, 40, and 50. Reference will now be made to an embodiment of an automated guided vehicle consistent with the present disclosure. Figure 2A-2I The manner in which this functionality is implemented is then described with reference to other figures depicting exemplary configurations of the FAM itself.

[0115] Vehicles

[0116] View now Figures 2A to 2I , showing an embodiment constructed according to the present disclosure and suitable for performing, for example, Figures 1A to 1C 200 for inventory management tasks in any of the material handling systems depicted in FIG. Each delivery vehicle is an automated guided vehicle having a first motorized drive system and a second motorized drive system and an onboard power supply. For use with an array of storage areas arranged in rows and accessible by a guidance system, such as Figure 1C As illustrated in the storage area 110 of FIG. 1 , the first motorized drive system of one or more embodiments cooperates with the guidance system to guide the movement of the vehicle along the corresponding vertical segments of the corresponding rows of adjacent storage areas. In such embodiments, the second motorized drive system is sized and arranged to maneuver the vehicle 200 on the underlying support surface while the first drive system is not engaged with the guidance system. Typically, the underlying support surface is defined by one or more areas of the warehouse floor and / or one or more higher platforms within the warehouse, or some combination of these.

[0117] Each carrier includes a transfer mechanism 210 for transferring items between, for example, a platform surface of the carrier and one of the plurality of destination areas 110. Figure 2A As best seen in FIG. 1 , in this example, the platform surface is defined by the outer surfaces of a plurality of rollers (indicated generally at 211). Figure 4B and 4C In more detail, each vehicle 200 may optionally include a clutch mechanism for engaging and disengaging the transmission of power from the motor of the first or second drive system to the transfer mechanism, so that the transfer mechanism can be operated as needed only when the first and second drive systems are not being operated to propel the vehicle.

[0118] The carrier 200 may incorporate any of a variety of mechanisms for loading items onto the carrier and for unloading items from the carrier into one of the storage areas. Additionally, the transfer mechanism 210 may be specifically adapted for a particular application. In the present example, the transfer mechanism 210 includes one or more displaceable elements configured to engage items stored at the storage location and pull the items onto the carrier. More specifically, in the present example, the carrier includes one or more displaceable elements configured to move toward a tote in the storage location. After the displaceable elements engage the tote, each displaceable element shifts away from the storage location, thereby pulling the tote onto the carrier 200.

[0119] See also Figure 2A , 2B2G to 2I, in this example, the transfer mechanism 210 includes two endless carriers such as drive belts or drive chains 214a and 214b1 as shown. Along each endless carrier such as chains 214a and 214b, a displaceable element ( Figure 2B , 2D , 2E). Each pin, such as pin 212a, extends inwardly toward the longitudinal centerline of the carrier. Optionally, a tubular bar element (not shown) can receive each of the pins 212a and 212b and extend across the width of the carrier 200.

[0120] In this example, one or more motors of the second drive system drive the chain to selectively move the chain and pins 212a and 212b toward or away from the storage position. For example, as the carrier approaches the storage position to retrieve the tote T ( Figures 2G to 2I ), the chain can drive the displaceable pins 212a and 212b toward the storage position so that the pins (and the bar connecting the pins, if any) are located below the grooves or notches in the bottom of the tote. The carrier travels upward a small distance until the pins 212a and 212b (or the bar) are seated with the grooves or notches, such as Fig.2I The chain is then reversed so that the pins 212a, 212b are moved away from the storage location 100. Because the pins engage the tote T within the recesses, the tote is pulled onto the surface of the carrier as the pins are moved away from the storage location. In this manner, the transfer mechanism 210 can be used to retrieve items from a storage location. Similarly, to transfer items stored in, for example, Figure 1C In a storage position such as the middle position 110, the chains 214a, 214b of the transfer mechanism 210 drive the pins 212 toward the storage position until the item is in the storage position. The carrier then moves downward to disengage the pins from the transport box, thereby releasing the transport box.

[0121] In the previous description, the transfer mechanism 210 has been described as comprising an endless carrier in the form of chains 214a and 214b and corresponding displaceable pin elements 212a and 212b that are optionally interconnected by a single tubular element. This arrangement is well suited for extracting totes containing items from storage areas arranged in vertical rows, wherein the tubular elements and / or bars extending therebetween fit within recesses in the bottom side of the tote near its leading edge. In one or more embodiments, the totes are placed in corresponding zones of the n-deep storage unit, wherein n Represents the maximum number of totes that can be accommodated one behind the other in a generally horizontal plane when all totes are coupled together and positioned in a single n-deep unit. Figure 1C A vertical array of such storage areas or cells, indicated generally at 110 , is depicted.

[0122] In this example, and if Figure 2H As best seen in FIG. 2 , two or more totes (e.g., totes T1 and T2) can be coupled and decoupled from each other using mating connectors, generally indicated at 283a and 283b, respectively. Totes T1 and T2 can be coupled and decoupled from each other through a series of lifting and uncoupling movements implemented by movement of carrier 210. Also, transfer mechanism 210 is actuated by a second drive mechanism to pull a forward (leading) tote onto rollers 211 ( Figure 2G ) so as to be fully supported by carrier 200. This pulling motion propels the trailing tote (i.e., the tote immediately behind the leading tote) into position toward the aisle. The first drive mechanism of carrier 200 is then briefly operated so that carrier 200 travels a vertical distance sufficient to decouple the leading tote from the trailing tote. Once the decoupling is complete, the second drive system is again briefly operated, this time to center the tote on carrier 200 so that the carrier and totes can be fully maneuvered vertically within the column.

[0123] exist Figure 2A and 2D In the illustrative embodiment depicted in FIG. 2F , the first drive system of the carrier 200 includes four wheels in the form of gears 220 that are driven to transport the carrier along a track disposed, as will be described in more detail later, along a track disposed in a row adjacent to the storage area 110. The wheels 220 are mounted on two parallel spaced axles, e.g. Figure 2F The axle 215 depicted in FIG. 2A and FIG. 2B is a perspective view of a wheel axle 215, with two wheels positioned along the forward edge of the vehicle and two wheels positioned along the rearward edge of the vehicle.

[0124] See specifically Figure 2C and 2F , Figure 2C yes Figure 2A 200 is a bottom view of the vehicle 200 depicted in FIG. Figure 2F yes Figure 2A A side elevation view of the vehicle depicted in FIG. Figure 2C As best seen in FIG, the vehicle 200 further includes a second drive system sized and arranged to propel the vehicle 200 on an underlying support surface, such as the floor of a warehouse or distribution center. Figure 2C In the illustrative embodiment of , the second drive system includes: a second motor of vehicle 200, generally indicated at 250a; and a third motor of vehicle 200, generally indicated at 250b. The second motor and the third motor are thus first and second motors of a second subset of the plurality of motors. By dynamically controlling the relative speed and / or rotational direction of each of motors 250a and 250b, it is possible to, for example, Figure 2F The vehicle 200 is driven in any direction on an underlying support surface of the surface S depicted in FIG.

[0125] Continue to view Figure 2C , it will be seen that the second drive system of the carrier 200 includes a first drive element 252a driven by a second motor 250a to rotate about a first rotation axis A1, and a second drive element 252b driven by a third motor 250b to rotate about a second rotation axis A2. Each of the first and second drive elements 252a and 252b are respectively sized and arranged to engage a corresponding portion of the underlying support surface S to effect movement of the carrier thereon. Figure 2C and 2F In the illustrated vehicle embodiment, the first rotation axis A1 is coaxial with the second rotation axis A2, and the drive elements 252a and 252b are supported by a flat horizontal surface. In this example, the second drive system of the vehicle 200 further includes a plurality of omnidirectional wheels, including a first pair of wheels 254a and 254b and a second pair of wheels 256a and 256b. The omnidirectional wheels are sized and arranged to frictionally engage corresponding portions of the underlying surface S ( Figure 2F ), wherein each of the wheels 254a, 254b, 256a and 256b is respectively fixed to a corresponding drive axle, such as axles 258a and 258b.

[0126] See specifically Figure 2C and 2D 2F, it will be seen that the carrier 200 may also incorporate a series of guides (indicated at 233) depending downwardly from the shaft 235. Each of the guides 233 is rotatably mounted to a lower portion of the shaft 235. The inventors have determined that in some applications, the guides 233 facilitate alignment of the carrier 212 as it is maneuvered on an underlying support surface and aligned with one or more other structures it may enter in the course of performing its assigned inventory management tasks. Figure 2C For example, it can be seen that some guide members 233 are arranged along the longitudinal center line L of the carrier 200. Figure 2E Depicts the alignment of guides 233 within a pair of parallel rails shown in cross-section and mounted on an underlying support surface S. In an exemplary application, rails R1 and R2 are arranged along a path by which carriers 200 enter, exit, and / or are maneuvered beneath a vertical array of storage units, such as Figures 12 to 13C Described in.

[0127] Now go to Figure 3A and 3B , Figure 3A It is across Figure 2A The cross section taken along line IIIA-IIIA in Figures 2A-2F A front elevation view of an exemplary automated guided vehicle of Figure 3B yes Figures 2A-2FA bottom plan view of an exemplary automated guided vehicle. Figure 3A , the first drive system further comprises a pair of inner idler pulleys 224a, 224b and a pair of outer pulleys 222a, 222b which, when driven by respective belts 226a, 226b, cause the geared wheel 220 mounted on the same shaft to rotate and thereby propel the vehicle 200 in a vertical direction in a row (along the drive surface of the track). The idler pulleys 224a and 224b rotate freely relative to the axle and maintain tension in the belts 226a and 226b. Each of the outer pulleys 222a and 222b is fixed relative to the axle 215 to which it is mounted. The first drive system further comprises a pair of counter-rotating gears 228a, 228b which are driven by the first onboard motor 230 ( Figure 3B ) rotate. When so driven, belts 226a and 226b drive pulleys 222a and 222b, respectively, and this rotational movement of pulleys 222a and 222b causes the geared wheel 220 mounted on the corresponding shaft 215 to rotate. Thus, when the carrier 200 moves vertically, the geared wheel 220 carries the weight of the carrier and any items thereon.

[0128] exist Figure 3A and 3B In the embodiment of the present invention, the drive axles 215 are rotatably mounted in the housing 232 so that their spacing relative to each other remains fixed. As will be described later, according to some embodiments, the fixed spacing between the axles 215 allows the vehicle to enter the vertical array ( Figure 1C ) and in which the guide system is installed, it is necessary to carry out an alignment step with the guide system (e.g. rails).

[0129] In an alternative embodiment (not shown), elements of the first drive system, such as the geared wheels 200 and axles 215, may be mounted within the housing 232 so as to allow them to be moved inwardly to relax any precise alignment requirements while also eliminating any risk of damage to the geared wheels 200 or the guide system. In the latter type of embodiment, a vehicle intended to carry a substantial load may require a motor-driven component to temporarily reduce the spacing between the axles 215 and thereby accommodate entry of the vehicle 200 into the row between the storage areas.

[0130] Continue to view Figure 3A and 3B, it will be seen that the first motor 230 is operatively connected to the gears 228a and 228b to drive the belts 226a, 226b and synchronously rotate both the axle 215 and the corresponding geared wheel 220. The first drive system of the vehicle 200 is thus configured to synchronously drive the vehicle 200 in a vertical direction relative to a track or other guide system. Specifically, each geared wheel 200 is connected to the end of one of the axles 215 so that the gear is substantially prevented from rotating relative to the axle. In this way, each axle synchronously drives the two attached gears. In addition, in this example, the two axles are synchronously driven so that all four gears are synchronously driven.

[0131] In an embodiment, a single drive motor 230 is used to drive two axles. In this example, pulleys 222a and 222b act as timing pulleys, which are rigidly connected to the axle 215 to prevent the pulleys from rotating relative to the axle. Similarly, timing pulleys (not shown) are connected to counter-rotating gears 228a and 228b driven by motor 230. In this example, a drive belt 226a connects timing pulley 222a with a timing pulley directly driven by motor 230 via gear 228a, and a drive belt 226b connects timing pulley 222b with a timing pulley indirectly driven by motor 230 via gear 228b. In an embodiment, belts 226a and 226b are each timing belts, so that the rotation of the drive motor 230 is accurately associated with the rotation of the axle.

[0132] Except for Figure 3A and 3B In addition to the illustrated single motor arrangement, there are various other mechanisms that can be used to synchronously drive the axle 215. For example, a pair of drive motors can be used to drive the axle, and the drive motors can be synchronized. In an embodiment, the drive motor 230 includes a sensor that can be used to detect the rotation of the motor, thereby determining the distance the vehicle has traveled. Because the gear 200 is rigidly connected to the axle, and the axle is synchronously connected to the drive motor 230, the vertical distance the vehicle moves can be accurately controlled to be related to the distance the drive motor 230 is displaced. For example, the sensor 252 can be a sensor such as a Hall sensor. The sensor detects the rotation of the motor and sends a signal to a central processor, which determines how far the vehicle 200 has traveled along the path based on known information about the specified path and the rotation of the motor detected by the sensor.

[0133] View now Figure 2C , 3B 4A to 4G, show an embodiment of the vehicle 200, the vehicle further comprising a clutch mechanism 400 ( Figure 4B and 4C ), the clutch mechanism may be engaged ( Figure 4C ) and detachment ( Figure 4B ) to respectively start and terminate the power transmission from the motor of the second drive system to the transfer mechanism, whereby the second drive system can be operated independently of the transfer mechanism. In this example, the clutch mechanism 400 can be configured as two clutch sub-assemblies, which are arranged symmetrically with respect to the longitudinal centerline of the vehicle 200, wherein these sub-assemblies are arranged in Figure 2C and 3B In the figure, the overall designation is 400a and 400b. Figure 4B and 4C , only the first clutch subassembly 400a is visible, and includes the first pivotable carrier 410. However, returning briefly to Figure 3B It will be seen that the second clutch sub-assembly 400b is constructed in the same manner as the sub-assembly 400a and therefore comprises a second pivotable carrier 412.

[0134] like Figure 4B As best seen in FIG. 1 , each clutch subassembly, such as first clutch assembly 400a, includes a pivotable carrier, such as first pivotable carrier 410, maintained in a first angular orientation relative to underlying support surface S with the entire weight of carrier 200 distributed between wheels 254a, 254b, 256a, 256b, 252a, and 252b. Figure 4C and Figure 4B By comparison, it should be understood that as the carrier 200 moves vertically in a direction away from the underlying surface S, the pivotable carrier 410 (and 412) is urged by the compressed coil spring 414 to the second angular position when the carrier 200 has reached at least 100 degrees above the surface S. Figure 4C The second angular position is reached when the dimension g1 shown in the figure is reached. Figure 3B It will be seen that the first driven element 270 is rotatably coupled to the first pivotable carrier 410, and the first endless loop element 274 transfers rotational power to the first driven element 270. Likewise, in the same manner as described for the first clutch sub-assembly, the second driven element (not shown) of the identically constructed second clutch sub-assembly 400b is rotatably coupled to the second pivotable carrier 412, and the second endless loop element (not shown) transfers rotational power to the second driven element.

[0135] In this example, each of the endless loop elements, such as endless loop element 274, is a belt, it being understood that chains could alternatively be used without departing from the spirit and scope of the present disclosure.

[0136] Continue to view Figure 4B and 4C, it will be seen that each clutch mechanism subassembly, such as subassembly 400a of carrier 200 constructed according to one or more embodiments, additionally includes a first pulley 280. The first pulley 280 and the first driven element 270 of subassembly 400a are driven by the second motor of carrier 200. Similarly, although not shown, the second pulley and the second driven element of subassembly 400b are driven by the third motor of carrier 200. In this example, the first pulley 280 and the second pulley are sized and arranged to engage the first endless loop element 274 and the second endless loop element, respectively, to drive the first and second driven elements whenever the corresponding drive motors rotate. That is, regardless of whether the clutch mechanism subassemblies 400a and 400b are engaged to drive the transfer mechanism, the first and second driven elements will rotate as the second and third motors, respectively, rotate.

[0137] As previously described, and in accordance with one or more embodiments consistent with the present disclosure, the carrier is lifted relative to the underlying support surface S by a dimension H ( Figure 4C ), the second and third motors are connected to engage the transfer mechanism. This lifting causes the pivotable carrier 410 to pivot away Figure 4B The first angle shown in the figure is oriented and enters Figure 4C . In this example, the coupling of the second motor to the transfer mechanism is achieved in the clutch mechanism subassembly 400a by the third driven element 272 pivoted into driving engagement with the first driven element 270. In a similar manner (although not shown), the coupling of the third motor to the transfer mechanism is achieved in the clutch mechanism subassembly 400b by the fourth driven element 272 pivoted into driving engagement with the second driven element.

[0138] like Figures 4A to 4C As shown in FIG. 1 , the third and fourth driven elements engaged are -- Figure 4C Rotation of the fourth driven element 272b, of which only the fourth driven element 272b is shown, causes the first sprockets 290a, 290b to rotate, which in turn causes the first and second chains 214a, 214b to move the container moving pin 212a (towards or away from the carrier 200) to be transferred to or from the carrier 200. Figure 4A ) and pin 212b ( Figure 4B ). When the wheels of the vehicle 200 rest on the surface S again, as shown in FIG. Figure 4B , the third and fourth driven elements are again decoupled from the first and second driven elements, respectively. Thus, continued operation of the carrier's second and third motors to propel carrier 200 on surface S no longer has any effect on transfer mechanism 210.

[0139] In some applications, it may be desirable to enable carrier 200 to load and unload items of a different kind than that configured as a tote sized and arranged to receive a plurality of inventory items. As illustrative examples, such other kinds of items may include boxes, cartons, pallets, etc., or any combination of these, and which may contain one or more items of inventory. In one or more embodiments, such items are accommodated by transfer mechanism 210 that incorporates alternative or additional unloading aids. See, in particular, Figure 2G and 4A 4D, it will be seen that the rotation of sprocket 290 causes chains 214a, 214b to drive sprocket 217, wherein each of the driven sprockets causes, for example, roller 211 ( Figure 2G The direction in which the pairs of sprockets 217 rotate determines whether the rollers of the transfer mechanism 210 are operated to assist in loading or unloading of items.

[0140] Figure 4D and 4E yes Figures 2A-2F 200, with the lateral exterior cover omitted to reveal an optional actuator mechanism 400 having a selectable position in a first position ( Figure 4D ) and the second position ( Figure 4E ) between which a force applying component 402 moves. Figure 4F yes Figure 4D and 4E 4 is an enlarged view of the actuator mechanism 400 depicted in FIG. 4 , with the force applying component 402 shown in a first, non-force applying position. Figure 4G yes Figures 4D to 4F 0 is an enlarged view of the actuator mechanism depicted in , with force application 402 shown in a second force application position.

[0141] As previously in Figure 4F As mentioned in the discussion of , the wheel 220 is mounted on two parallel and spaced axles, such as Figure 2F 215, so that two wheels are disposed along the forward edge of the vehicle and two wheels are disposed along the rearward edge of the vehicle. In one or more embodiments, the optional actuator mechanism 400 includes a threaded portion 404 of each axle 215 and a corresponding pair of carriers 406. Each corresponding carrier 406 has a corresponding threaded hole that is sized and arranged to receive the threaded portion 404 of the axle 215 and carry one of a pair of force applying members 402. In one or more embodiments, the force applying member is a roller that is free to rotate within the carrier 406 about an axis of rotation that is transverse to the axis defined by the axle 215.

[0142] In order to provide better steering control that can be obtained by differentially driving the front or rear omnidirectional wheelsets, the inventors have determined that the force application component 402 can be selectively actuated without the need for a dedicated motor. In this example, the motor 230 ( Figure 3B ) causes the axle 215 to rotate, which causes the carriers 406 to move forward until they encounter a stop, whereby continued rotation of the axle 215 does not cause the carriers 406 to move further. Figure 4G When positioned as shown, each force applying member applies a normal force on the surface of one of the wheels, for example when wheels 252a, 252b are being driven by the second and third motors, respectively. Such actuation of the force applying members 402 increases the frictional contact of wheels 252a and 252b, and thereby increases the frictional contact of wheels 252a and 252b when the vehicle 200 moves across the underlying surface S ( Figure 4G ) provides better directional control when the vehicle is in a storage area 215. Because the wheels 252a, 252b are only needed when the vehicle is outside the array of storage areas 215, the motor 230 and the axle 215 can serve a dual purpose.

[0143] Therefore, continue to see Figure 3B and 4D 4G, it will be seen that in some embodiments, the carrier 200 includes a first pair of motor-driven omni-directional rollers and a second pair of motor-driven omni-directional rollers, wherein the first omni-directional rollers of each pair are sized and arranged to rotate about a first rotational axis, wherein the second omni-directional rollers of each pair are driven to rotate about a second rotational axis, and a fifth roller is driven by one of the first motor and the second motor; and an actuator that is movable from a first position to a second position to selectively urge the fifth roller in a direction toward an underlying support surface; wherein a surface of each of the first and second pairs of omni-directional rollers and a surface of the fifth roller are sized and arranged to contact the underlying support surface when the actuator is maintained in the first position, and wherein movement of the actuator to the second position causes a load to be transferred from one or more of the omni-directional rollers to the fifth roller.

[0144] In one or more embodiments, the vehicle 200 may be powered by an external power supply, such as contacts along a continuous charging track, or alternatively powered using an inductive power transfer coil, either of which is used to provide the power required to drive the vehicle. However, in the present example, the vehicle 200 includes an onboard power supply that provides the power necessary for both the first drive motor 230 and the motor that drives the second drive system. In an embodiment, the onboard power supply is rechargeable. In this regard, the power supply may include a power source such as a rechargeable battery, such as a capacitor 240 ( Figure 3B), or a combination of these. For example, the supercapacitors can accept extremely high amperages during recharging operations. By using high currents, the supercapacitors can be recharged in a relatively very short period of time, which can be measured in seconds or minutes, compared to the hours that may be required to charge a suitable battery. On the other hand, the process of preparing to replace a discharged battery with a recharged battery can be automated according to one or more embodiments as part of the process of operating one or more of the vehicles.

[0145] Where charging rails are used, each carrier 200 includes one or more contacts for recharging the power source. In the present example, the carrier includes a plurality of brushes, such as copper brushes, which are spring loaded so that the brushes are biased outward. The brushes cooperate with the charging rails to recharge the power source, as further described below. For example, a pair of charging rails (not shown) may be arranged along a row within which the carrier 200 moves during a sequence of one or more storage and / or retrieval tasks. Alternatively, vertical and / or horizontal charging rails may be arranged at a location disposed at a delivery station 120 ( Figure 1C ) at a nearby charging station (not shown).

[0146] In an embodiment, the charging rail is a conductive strip connected to an electrical supply. The charging contacts of the vehicle 200 engage the conductive strip to recharge the supercapacitors. Specifically, the biasing elements of the brushes bias the brushes outward toward the charging contacts. The power flowing through the charging contacts provides a high amperage, low voltage source that allows the supercapacitors to be recharged in intervals that can be measured in seconds or minutes, depending on the amount of power consumed during the sequence of inventory management tasks or subtasks.

[0147] Because the power supply provided by the supercapacitors can last only a few minutes, a vehicle utilizing supercapacitors as a power source can be recharged each time the vehicle travels within a load train and / or utilized along the way while performing tasks requiring communication with one or more FAMs (e.g., FAM 18 ( Figure 1A and 1B ) or FAM 40 and 50 ( Figure 1B and 1C )) The path taken during the associated inventory management task of placing the charging stations.

[0148] In one or more embodiments, each carrier may include a load sensor for detecting the loading of items onto the carrier. The sensor ensures that the items are properly positioned on the carrier. For example, the load sensor may include a force detector that detects changes in weight, or an infrared sensor that detects the presence of an item.

[0149] exist Figures 1A to 1CIn embodiments of the present disclosure, the automated guided vehicle or AGV may be semi-autonomous or alternatively fully autonomous. In the latter aspect, numerous contactless systems have been proposed for continuously determining the actual position of an automated guided vehicle in absolute coordinates, and resetting navigation parameters (i.e., X, Y, and heading) to remove accumulated errors, thereby re-reference the vehicle. Any of these may be utilized in embodiments of position reference of automated guided vehicles in inventory management systems consistent with embodiments of the present disclosure. Such reference systems may be ultrasonic, RF, or optical in nature, with ultrasonic and optical being particularly suitable for indoor scenarios. Of the latter two categories, optical systems are generally more accurate and therefore more widely adopted in commercial practice.

[0150] An exemplary position sensing system utilizes a scanning mechanism that operates in conjunction with fixed position references placed at key locations at predefined survey sites. Such scanning mechanisms may include scanning detectors with fixed active beacon transmitters, scanning transmitter / detectors with passive retro-reflective targets, scanning transmitter / detectors with active transponder targets, and rotating transmitters with fixed detector targets.

[0151] In one or more illustrative embodiments consistent with the present disclosure, automated guided vehicles rely on a scanning laser triangulation scheme (SLTS) to provide position updates for the vehicle's onboard dead reckoning system. A laser transmitter rotating at, for example, 2 rpm illuminates a passive retro-reflective barcode target attached to a wall or support column at a known location approximately fifteen meters from the vehicle. The barcode is used to positively identify the reference target and eliminate ambiguity due to false reports from other specular reflective surfaces in the operating area. Each vehicle's onboard computer calculates XY position updates through simple triangulation to remove accumulated dead reckoning errors.

[0152] By way of additional example, each automated guided vehicle 200 may utilize retro-reflective targets distributed throughout the operating area, allowing both range and angular orientation to be determined by each vehicle. In one embodiment, a servo-controlled rotating mirror on the AGV translates a near-infrared laser beam up to a horizontal arc of 90 degrees at, for example, a 20-Hz update rate. As the beam sweeps over a target of known size, a return signal of limited duration is sensed by the detector. In the case where the retro-reflective targets are all the same size, the signal generated by the near target will have a longer duration than the signal from the far target. Angle measurement begins when the scanner begins to sweep from right to left, with the timing sequence terminated by detection of the reflected signal.

[0153] Yet another position reference technology that may be employed in automated guided vehicles consistent with the present disclosure is a laser-based scanning beacon system that uses cooperating electronic transponders and passive reflectors to calculate vehicle position and heading. Such a scanner mechanism includes a rotating reflector that is attached to the vertical shaft of an incremental optical encoder at, for example, a 45-degree angle. To achieve increased azimuth accuracy, a timer interpolates between encoder counts. The fan-shaped beam diverges vertically at, for example, a four-degree spread angle to ensure long-range target detection when traversing irregular floor surfaces. Each target is uniquely encoded, and many (e.g., 32) targets can be processed in a single scan, with the vehicle XY position calculated every 100 milliseconds.

[0154] In one or more autonomous embodiments, each AGV maintains in memory an internally stored map of its own location within the facility. In addition, each AGV reports its position in the plane of travel, speed, angular orientation, and selected path of travel data to other vehicles in the facility, and the AGV receives this data from other vehicles. Using the AGV data, each vehicle maintains a dynamically updated map that reflects the locations of all vehicles in a particular zone of the inventory management facility to which the vehicle has been assigned. When the dynamically updated location data is available locally on each vehicle, a task may be assigned to the vehicle by a central controller (e.g., controller 450), and in an embodiment, the vehicle may select a route segment to be taken by the vehicle to reach the location of the element in which the assigned task is to be performed.

[0155] In one embodiment, each vehicle is configured to execute steps of a navigation process stored in a memory via a processor local to the vehicle, the steps causing the vehicle to follow the shortest path from the vehicle's current location to the destination where the next (some) subtasks of the assigned task will be performed. In such embodiments, the central controller 450 need not be configured to perform traffic control and collision avoidance functions (unless a back-up control scheme is required), but in fact, the central controller 450 may be configured to transmit signals representing instructions that identify the next (some) tasks to be assigned to each vehicle and specify the various locations within the facility where those tasks will be performed. On the other hand, the vehicle may be configured to transmit signals to the controller, the signals representing task assignment confirmation, location updates, status updates (e.g., subtasks completed or in progress, current power status, etc.), and other information that the controller may need to assess the relative ability of the vehicle to perform the tasks to be assigned.

[0156] In a fully autonomous scenario according to one or more embodiments, each vehicle may alternatively utilize a local processor to determine speed and direction of movement from sensed landmarks placed on underlying support surfaces in one or more areas of the inventory management facility, exchange such position data with other vehicles within the facility, and maintain a dynamically updated local map to implement a form of decentralized traffic control in a manner similar to that described above using other position sensing methods.

[0157] In a semi-autonomous configuration of an AGV consistent with the present disclosure, a central controller, such as controller 450, provides traffic control functions required, for example, to prevent vehicles from colliding with each other and / or with any potential obstacles to the movement of vehicles that may be present in the one or more zones of the facility to which the subset of vehicles is assigned. In such embodiments, the controller 450 receives current position and orientation data in the form of an update signal transmitted from the vehicle 200. In an embodiment, the received position and orientation data is compared with estimates that the controller has derived from previous speed and heading instructions transmitted by the controller to the vehicle. Based on the comparison, the controller 450 can determine whether one or more of the speed and direction of one or more vehicles needs to be corrected to prevent collisions, and if so, transmit those instructions to the vehicle.

[0158] In one or more semi-autonomous embodiments consistent with the present disclosure, each carrier 200 may include a reader for reading a data item placed on a surface on which the carrier is traveling and / or within a lane column that corresponds to a storage area 115 ( Figure 1C ) in a position aligned with an array of . In some embodiments, each marker of the first group of markers corresponds to a unique position to form a grid of positions. These positions may be stored in a data table in a memory accessible by a processor of the vehicle, the central controller 450, or both. By following a path designed to intersect a specific sequence of these markers, each vehicle may transmit an identifier of the marker when it passes through the marker and confirm the identifier to the controller 450, thereby achieving semi-autonomous guidance of the vehicle through instructions transmitted to the vehicle by the controller. Based on this information and other data reported by each vehicle, the controller 450 may confirm the speed, direction, and path of movement of each vehicle. In one or more embodiments, the controller 450 utilizes speed and direction data to implement a collision avoidance strategy, assign inventory management tasks based on the position and power reserve status of each vehicle, and maintain an appropriate distance from any personnel permitted in the area for safety reasons.

[0159] Additional markings may be attached within the aisle array or to the stored totes themselves, adjacent to each storage location 115 ( Figure 1C) location. Here, each sign may include a unique bar code, and a reader on each carrier 200 may scan the area around the storage location 115 where the item is to be delivered or picked up. The data that the central processor 450 has about the path that the carrier 200 must follow and the data about the distance the carrier has traveled based on the data about the rotation of the drive motor may be sufficient to determine whether the carrier 200 is positioned at an appropriate storage location within the storage area 115. However, the signs of the adjacent storage areas permit redundant checks of the position of the carrier before the items are unloaded into or received from the appropriate storage location. Therefore, a scanner can be used to scan and read information about the storage location at which the carrier stops. If the scanned data indicates that the storage location is an appropriate storage location, the carrier unloads its items into the storage location. Similarly, the carrier may have a second reader for reading a sign adjacent to the rear edge of the carrier. The second reader may be used in applications where the system is configured to utilize a first series of storage locations along the forward side of the channel column and a second series of storage locations along the rearward side of the channel column, such as Figure 1C As shown in .

[0160] In some embodiments, functionality for autonomous or semi-autonomous guidance of vehicle 200 may be integrated into one or more of the FAMs (e.g., Figure 1A Such an approach may be beneficial in situations where accurate location sensing is required in some areas within an inventory management facility, but less accurate location sensing methods may be acceptable in other areas. For example, in Figure 1A In the embodiment depicted in , the FAM 18 is depicted as acting in a support role for the warehouse worker, and thus may be required to maintain a safe distance, but still remain nearby to perform support tasks. Based on the above discussion of various non-limiting examples, it can be said that a variety of techniques and systems can be employed in order to coordinate the location of AGVs and associated FAMs in an inventory management system.

[0161] In the above description, the carrier has a drive gear 220 that is sized and arranged to interact with the teeth of a corresponding inward track disposed within each channel column. This interaction can achieve raising or lowering of the carrier depending on the direction of rotation of the motor 230. Moreover, one or more of the FAMs may incorporate a track with teeth to allow the carrier to raise and lower the FAM associated with it and one or more of the structures that interface with the FAM (e.g., FAM 18 or FAM 50). In addition, the teeth of the drive gear 220 may alternatively be actuated to actuate a mechanism that is part of the FAM. As will be described later, for heavier loads (e.g., about 300 kg or more), for example Figure 1B and 1CThe multi-shelf FAM 40 depicted in may be equipped with an internal gear-driven jack mechanism that is actuated by rotation of gear 220 in order to minimize the amount of torque required by motor 230 to initiate and maintain lift of the FAM 40 during its movement over an underlying surface.

[0162] In some embodiments, the processor of each vehicle controls the operation of the vehicle in response to signals received from the central processor 450. In addition, the vehicle includes a wireless transceiver so that the vehicle can continuously communicate with the central processor as it travels along the track. Alternatively, in some applications, it may be desirable to incorporate multiple sensors or indicators along the path that the vehicle can traverse. The vehicle may include a reader for sensing sensor signals and / or indicators, and a central processor for controlling the operation of the vehicle in response to the sensors or indicators.

[0163] Figure 5A is a front perspective view depicting the use of an automated guided vehicle 512 in conjunction with a first group of functional attachment modules (FAMs) 518 in accordance with one or more embodiments. Figure 5B is a diagram illustrating a method according to a corresponding embodiment Figure 5A 512 and a first illustrative substrate 514, which may be implemented as a component of a functional attachment module, implemented as Figures 1A to 1C 5A, or implemented as a separate functional accessory module that acts as an adapter between the carrier and at least one of those other types of functional modules. Where FAM 518 is intended to accommodate heavier loads, base 514 may incorporate an internal receptacle mechanism actuated by a gear (e.g., gear 515) that is sized and arranged with large gear 520 of carrier 512.

[0164] Figure 5C is a perspective view depicting a post-docking alignment of an automated guided vehicle 512 with a second alternative substrate 516, which may be implemented as a component of a functional attachment module, implemented as Figures 1A to 1C and any of the functional accessory modules shown in 5A, or implemented as a separate functional accessory module that acts as an adapter between the carrier and at least one of those other types of functional modules.

[0165] Figure 5D The automated guided vehicle 512 and the Figure 5C Or a rear elevation view of the docked substrate 522 depicted in 5D, where respective surfaces of each of the substrate and carrier contact the underlying support surface S at a plurality of points 524a. Figure 5EAfter the first drive system of the carrier, including the front and rear pairs of geared wheels (e.g., wheels 526a and 526b), has been actuated by rotating large gear 520 in the direction of the arrow to lift the substrate docked therewith so that none of the surfaces of the substrate (including surface areas 524a and 524d) are in contact with the underlying support surface S Figure 5D 512. In this example, the base 514 incorporates an internal receptacle mechanism that includes linearly extendable legs 528a and 528b that are displaced downward as the large gear 520 rotates to drive one or more gears (e.g., gear 515) of the drive mechanism.

[0166] Fig. 6A is a perspective view depicting a post-docking alignment of an automated guided vehicle 612 with a third alternative substrate 614, which may be implemented as a component of a functional attachment module (FAM), implemented as a Figures 1A to 1C 5A, or implemented as an auxiliary (FAM) sized and configured to act as an adapter between the carrier and at least one or more of those other types of FAMs. In this example, the base 614 is sized and arranged to allow the carrier 612 to enter, lift and transport the FAM 618 ( Figure 6C )'s auxiliary FAM.

[0167] To accommodate entry of the carrier 612, the base 614 of the auxiliary adapter defines a central entrance having transverse recesses generally indicated at 615a and 615b. Figure 6B (It is Fig. 6A As can be seen in the rear elevation view of the docked automated guided vehicle 612, each of the transverse recesses 615a and 615b is aligned with a corresponding segment of the track (e.g., track segments 616a and 616b, respectively). Track segments 616a and 616b are attached to the inner surface of the base 614 and aligned with each other so that the two track segments are vertically oriented when the bottom surface 617 of the auxiliary adapter rests on a generally horizontal underlying support surface.

[0168] The carrier 612 may utilize a gear and axle pulled together by an appropriate mechanism (not shown) to accommodate docking with any of the one or more FAM structures described herein and / or to be described. In other embodiments consistent with the present disclosure, the distance between the gears 620a and 620b remains fixed during the execution of all inventory management tasks including all phases of the carrier alignment, FAM entry, and FAM docking procedures. In such embodiments, precise alignment between the geared wheels of the carrier 612 on the one hand and the track segments (e.g., segments 615a and 615b of the carrier base on the other hand) must be maintained.

[0169] To this end, one or more FAM embodiments may incorporate revocable interlocking structures, such as protrusions (not shown), as an illustrative example. Fig. 6A and 6B The auxiliary FAM of 217 may include a protrusion extending downwardly from the bottom surface of 217, wherein one or more drive systems of the carrier 612 are actuated to lower and raise the protrusion into and out of a recess of a set size formed, for example, by drilling, into the underlying support surface S. This arrangement may alternatively be reversed so that a recess is defined in the bottom surface 617, and the protrusion is attached, fixed or otherwise formed so as to protrude upwardly from the underlying support surface S.

[0170] The revocable engagement between the protrusions and recesses as described above is one-way to maintain the position of the substrate 614, resisting undesirable lateral displacement movement that may otherwise occur, for example, during deceleration of the carrier and FAM due to unexpected impact forces applied during the docking procedure. Improper alignment between the large gear of the carrier 612 and the FAM during docking is a source of potential impact. To this end, a sensor of the carrier 612 may be used to initiate a realignment procedure, by which the carrier 612 may back off, make small angle adjustments and attempt to re-enter the substrate 614. However, in one or more embodiments consistent with the present disclosure, a carrier consistent with the present disclosure is configured to utilize an alignment system to facilitate proper registration of the carrier's large gear (e.g., the large gear 620a-620c of the carrier 612) with those FAM structures (e.g., the substrate 614) that utilize track segments.

[0171] The use of an alignment system minimizes the possibility of damage to either of the two structures (gearwheel and track segment) during the docking procedure. Fig. 6A and 6B In an embodiment of the present invention, the alignment system includes parallel floor mounted rails, such as rails 632 and 634. Rails 632 and 634 are separated by a gap that is sized to receive and guide the linear translation of one or more supports depending downwardly from carrier 612. That is, rails 632 and 634 are separated along their length by gaps of sufficient width to accommodate the entry and passage of a series of guides, generally indicated at 633. Each guide is connected by a bar ( Figure 6B ) is suspended from the base frame of the carrier 612.

[0172] Go to briefly Figures 2C to 2F It will be seen that the carrier 200 also incorporates a series of guides indicated at 233 . Figure 2C As can be seen in FIG. 6 , these guides are arranged along the longitudinal center line L. In an embodiment, the guides 233 are arranged along the bottom side of the carrier 612 to be aligned with the guides for the Figure 2C633 in the guide member 635 is arranged in the same manner as the way shown. When all guide members 633 have entered the gap between rails 632 and 635, the appropriate alignment between the carrier 612 and the base 614 (or any other FAM and storage structure depicted throughout this disclosure) can be maintained. In the previous aspect, it should be noted that the gap between rails 632 and 634 can be tapered from a larger width dimension (at the leading guide member entry point) to a smaller width dimension, so as to, for example, relax the burden of the carrier 612 starting to dock with the same tight dimensional tolerance originally required on the entry point at the base 614 of the auxiliary adapter FAM itself. In some embodiments, the tapering can be monotonous in the entry transition zone. That is, the width of the gap can be reduced at a constant rate in the direction in which the carrier moves toward the FAM docking therewith, and thereafter, the gap between the rails can maintain a constant width, and the constant width is selected to maintain the sufficiently accurate alignment of the carrier with its entry point to the FAM. In the case of a carrier equipped with a gear wheel (such as carriers 212 and 612), this alignment will be determined by the spacing of the corresponding teeth of the FAM guide or socket system that will interact with the gear wheel.

[0173] Once the vehicle 612 is maneuvered into position properly aligned with the base 614, one or more drive systems of the vehicle 612 are operated so that its wheels (including the omnidirectional wheels 654a ( Fig. 6A ) and 656a and 656b ( Figure 6B )) causes the carrier 612 to enter the base 614. In an embodiment, the motor (not shown) of the first drive system of the carrier causes the large gears 620a and 620b to rotate in the direction of the arrows shown. The large gears rotate against the teeth of the shelf segments (e.g., shelf segments 616a and 616b) causing the base 614 to be pushed upward in the direction of arrow F. Once the carrier 612 has lifted the base 614 docked therewith, the bottom surface 617 of the base 614 is no longer in contact with the underlying support surface S.

[0174] Figure 6C It is based on the description Figures 5A to 6B618. A perspective view of an inventory management system 600 for placement and use of a plurality of functional attachment modules 618 constructed in accordance with any of the embodiments shown in FIG. 618. In this case, a carrier 612 is shown disposed within a substrate formed as an integral part of each FAM 618. Each FAM 618 includes a plurality of bins (e.g., bins 618a and 618b) mounted along a handle 619 so as to be at the correct height above the ground floor for a human operator H to remove items from a nearby storage shelf and place them into one of the bins. Operator H can then confirm the conclusion that the transaction is complete by entering data via a touch screen terminal (e.g., touch screen terminal 621). In this example, a second operator O at a picking destination removes items from bins 618c or 618d and places them in cartons C for shipment.

[0175] View now Figures 7A to 7D , you will see, Fig. 7A is a perspective view depicting a pre-docking alignment of an automated guided vehicle 712 and a first functional attachment module (FAM) 714, the first functional attachment module being a carrier 712 and Figures 1A to 1C In the form of an auxiliary adapter FAM between at least one or more of the other types of functional modules shown in FIG. Fig. 6A and Figure 6B In the exemplary embodiments described above, Fig. 7A and 7B Embodiments of the invention may utilize a revocable interlock system and an alignment system (neither of which are shown) to facilitate the docking that must occur between the carrier 712 and the auxiliary FAM 714. To facilitate the functionality of the auxiliary FAM 714, namely, to elevate one or more dynamically deployable FAM structures (e.g., Figures 8A to 8C The upper surface of FAM 714 may also include a plurality of upwardly extending docking protrusions, generally indicated at 715. In an embodiment, protrusions 715 are sized and arranged to engage with corresponding structures (e.g., Figures 8A to 8C When docked, the protrusion 715 of the FAM 714 forms part of a revocable interlock with any auxiliary FAM structure when both are being transported across the underlying support surface S by the carrier 712.

[0176] Figure 7B is a depiction of the semi-autonomous vehicle 712 and Fig. 7A A perspective view of the alignment between the functional accessory modules 714 after docking. Figure 7C yes Figure 7B724a, 724b, 724c, and 724d, respectively, in contact with the underlying support surface S. Fig.7D After the first drive system of the carrier including geared wheels 720a and 720b has been actuated to lift the first functional accessory module so that none of the surfaces of the first functional accessory module 714 (including surfaces 724a and 724d) are in contact with the underlying support surface Figure 7B A rear elevation view of the docked automated guided vehicle 712 and the first functional accessory module 714.

[0177] View now Figures 8A to 8C , you will see, Fig. 8A It is a depiction Fig.7D 7 and a partial elevation view of a docked guided automated carrier 712 and a first or secondary functional attachment module (FAM) 714 aligned prior to docking with a second functional attachment module (FAM) 718, which in this exemplary embodiment is implemented as a multi-layer storage rack having storage shelves 719. The shelves 719 of the FAM 718 define corresponding storage surfaces 719a that accommodate items such as containers C of inventory items (e.g., Fig. 8A and 8B ) and / or individually boxed inventory items placed directly on surface 719a (such as Figure 8C ). According to one or more embodiments, FAM 718 also defines floor contacting surfaces 724e and 724f that are sized and arranged to support the shelf on an underlying support surface.

[0178] Figure 8B is depicted after the first drive system of the carrier, including the large gears 720a and 720b, has been actuated to further lift the first FAM 714 and also lift the second FAM 718 so that no surface of the first or second FAM contacts the underlying support surface S. Fig.7D and 8A A partial elevation view of a docked vehicle 712 and a first or auxiliary FAM 714 aligned with a second FAM 718 after docking. Figure 8C is depicted in Figure 8B 714 and the second FAM 718 are shown in a full elevation view of the relative positions of the guided automated vehicle, the first FAM 714 and the second FAM 718 after the second FAM 718 is lifted and transferred to another location in the manner shown in FIG.

[0179] A FAM such as FAM 718 may be required to support and store a collection of heavier items (e.g. Figure 8C), where the total weight of the FAM 718 and the items stored thereon approaches 400 kg or even more. The inventors have determined that the additional contact force supplied to the non-omnidirectional drive elements can improve the maneuverability of the vehicle transporting a heavily loaded FAM. Returning briefly to Figures 4D to 4G It will be recalled that a vehicle consistent with the present disclosure (e.g., vehicle 200 or vehicle 712) optionally includes a force applying component 402. The force applying component 402 can be selectively moved from a first or initial position ( Figure 4D ) moves to the corresponding driving element of the carrier 200 or 712. The force applying member 402 is actuated from its initial position to the second position ( Figure 4E In an embodiment, the force applying member 402 is a roller that can rotate freely around a corresponding rotation axis within the carrier 406. When moved into its corresponding second position, as shown Figure 4E and 4G , each roller 402 applies a normal force against the surface of the drive element on which it is positioned. The application of this normal force in turn increases the frictional contact between the drive element and the underlying support surface.

[0180] like Figure 4E As best seen in FIG. 1 , sufficient force FN may be applied to lift one or more of the omnidirectional wheels so as to form a gap g between each wheel and the underlying support surface S. w In practice, the gap g w will fluctuate and be different for each of the omni wheels at any given moment when the vehicle 200 is transporting the FAM 718. That is, equal gap g between the front and rear omni wheels is made to indicate a perfectly balanced load. w of Figure 4E The appearances shown are only momentary.

[0181] It is suffice to say that carrier 712 need not include force applying member 402 or similar structure to enhance frictional contact with an underlying support surface, particularly where a FAM (e.g., FAM 718) carrying many or heavy items will not be utilized in the performance of inventory management tasks. As an illustrative example, for example Figure 1CThe arrangement depicted in may omit FAM718 entirely. However, in the present example, vehicle 712 includes force application component 402, and a first onboard motor is used to independently rotate one of the central drive elements (e.g., drive element 752b), while a second onboard motor is used to independently rotate another of the central drive elements. In this embodiment, rotation in either direction is achieved by rotating the central drive elements in opposite directions or in the same direction (but one faster than the other) for a larger turning radius. In addition, the omnidirectional wheels on one side (e.g., wheels 754b and 756b) may be driven by the same onboard motor used to drive the central drive elements on that side. By way of another example, a single third onboard motor may be used to drive all of the omnidirectional wheels, as previously described in conjunction with vehicle 200. In any of the above examples and other examples, the transfer mechanism may be driven by yet another onboard motor, thereby avoiding the need for a clutch mechanism.

[0182] Fig. 9 900, which includes a first FAM module 714 and a second FAM module 718, a respective group of which the automated guided vehicle 712 is adapted to cooperate with to perform a corresponding subset of inventory management tasks, and a group of which the automated guided vehicle 712 is adapted to cooperate with to perform yet another subset of inventory management tasks. Specifically and as will be described later, Fig. 10A and 10B In the manner described, vehicle 712 is further sized and arranged to enter, lift, transport, and move vertically within a mission completion zone Z surrounded by adjacent pairs of columns 929a and 929b of FAMs 918.

[0183] Within the task completion zone Z, the carrier 712 may be configured through operation of its drive system to cooperate with the guidance system of the FAM 918 and thereby lift containers, boxes, cartons and / or pallets for transferring individual inventory items or, in the alternative, supporting multiple items of inventory. Such item(s) are transferred to a storage area of ​​the multi-level flow rack structure 920 positioned adjacent to a destination area containing a picking station PS through operation of a transfer mechanism such as individual drive rollers (e.g., rollers 711 of the carrier 712). In this example, and as Fig. 10B As seen in FIG. 8 , the guide system includes track segments 926 that are fixed or attached to or otherwise formed on the inwardly facing surfaces of columns 929a and 929b.

[0184] At locations proximate to the picking station PS, one or more mobile rack structures (e.g., rack structure 920) may supply the picking station operator with those inventory items that are needed or expected to be needed based on demand forecasts to satisfy inventory management requests during upcoming inventory management intervals (e.g., to satisfy e-commerce or mail order orders during one or more upcoming picking cycles). Such rack structures may be supplied by dynamically movable (and removable) FAMs 918, such as Fig. 9 and 10A Additionally or alternatively, FAM 918 may be permanently attached to shelf structure 920 so that a carrier (e.g., carrier 712) may utilize an already existing FAM to accomplish assigned inventory management tasks, such as transferring items to a delivery area of ​​shelf structure 920.

[0185] When other inventory management tasks do not otherwise require, or during times when the shelf structures 920 are being replenished at a high rate, a subset of the total number of carriers 712 deployed at a given facility may be reserved for use in one or more of the mission activity zones Z of the corresponding FAMs 918. Replenishment of items to storage areas of the shelf structures 920 during such times may be accomplished by actuating a transfer mechanism (e.g., rollers 711) of an arrival carrier 718 to shift items from the arrival carrier to a carrier 718 already positioned within the mission activity zone of the FAM 918. Coordination of movement between the arrival carrier and the "local" transfer carrier may be through peer-to-peer communication between the carriers, or it may be directed by a central controller.

[0186] Carriers and FAMs configured in a manner consistent with the present disclosure may be used with a variety of mobile racking structures 920. Some mobile racking structures may use unpowered rollers to feed items to the picking station PS for one-way feeding assisted only by gravity. Alternatively, and as Fig. 9 As shown, the shelf structure 920 can utilize a bidirectional network of parallel belts 932 or other conveying elements to propel items toward or away from the picking station PS. In this embodiment, the feeding of objects transferred to the picking station by one of the carriers 718 requires driving one or more of the belts 932 in a first direction away from the carrier and toward the picking station.

[0187] In contrast, removing items from the shelf structure 920 requires a reversal of the aforementioned carrier to shelf structure process. This reversal may be warranted, for example, when a different subset of items is to be stored in the shelf structure 920 in preparation for a new item picking cycle. Additionally or alternatively, items currently stored on the surface of the belt 920 may no longer require the same amount of picking as before during the current and upcoming picking cycles. In this regard, areas reserved for fast moving inventory items (e.g., Fig. 9Redistribution of items between remote areas (exemplified by the placement of mobile rack structures 920 in the central storage area) and those remote areas that are more suitable for slower moving inventory items may be advantageous in order to maintain an acceptable shorter average travel time for each picker. For example, during off-peak times, when fewer agents are available to extract items for picking from remote storage areas, greater efficiency can be achieved by temporarily introducing some slower moving items into rack structures 920 via carriers 718. This action provides the agents with access to these items during one or more off-peak inventory management intervals. In preparation for subsequent intervals in which, for example, more pick and place agents are available, the slower moving items are moved back into the remote storage areas.

[0188] In one or more embodiments, the carrier 718 incorporates a discharge aid (not shown) that operates in conjunction with the carrier's transfer mechanism to align items being transferred from the carrier to a target area of ​​the shelf structure 920. In order to transfer items from one of the carriers 718 to a specific subset of the belts 932 of the mobile shelf structure 920, the controller of the carrier is configured to operate the discharge aid to push the items to transfer in a direction transverse to the direction in which the carrier's transfer mechanism pushes the items toward the subset of belts 932, thereby establishing and maintaining the necessary alignment. As an illustrative example, the discharge aid includes a push rod (not shown) that is sized and arranged to protrude from one of the two side walls of the carrier 718 above the support plane defined by the uppermost surface of the rollers 711.

[0189] As an extension of the dynamic inventory allocation using carriers and FAMs consistent with the present disclosure, and continuing to refer to Fig. 9 , it will be appreciated that other inventory items may be stored on shelves of the first subset of FAMs 718 (indicated at 718a) closest to the picking station. Items that are less frequently needed than the items stored in FAM 718a and / or mobile rack structure 920, but will need to be accessed at some point during the current or upcoming inventory management cycle, may be stored in a second subset of FAMs 718 (indicated at 718b) that is slightly further away from the picking station PS. Still other subsets of FAMs 718 (not shown) for storage of items that are not needed during the current or upcoming inventory management cycle may be located further away than FAM subsets 918a and 918b.

[0190] Fig. 9Also shown in the figure is an additional carrier 712 carrying container C1 directly away from the picking station operator after the contents of container C1 have been removed and transferred to one of the shipping boxes C2 being moved by the outfeed conveyors 922 and 924, respectively. In some embodiments, carton C1 is lifted by carrier 712 after being maneuvered into a position below the work surface WS in front of the operator. To this end, an aligned inward track segment (not shown) is provided for the carrier to enter and move upward by rotating the large gear in a first direction that brings carton C1 into a position displayed in front of the operator. Once the desired number of items have been removed from carton C1, the large gear of the carrier is operated in the reverse direction, thereby lowering the carrier so that it can be deployed for the next scheduled inventory management task assigned to it.

[0191] Suffice it to say that multiple distinct inventory storage modalities are achieved using carriers and FAMs configured in accordance with embodiments of the present disclosure, and that inventory therein is dynamically employed and repositioned during each inventory management window. This is true whether the window extends across the entire inventory management cycle (which can be six hours to a full 24 hours, including picking and replenishment operations), or whether the window is subdivided into multiple intervals to better match fluctuations in both demand for specific inventory items and the availability of human resources to handle them. Furthermore, those same carriers can extract and return items to statically positioned storage areas, further enhancing the efficiency of the warehouse facility during the inventory management cycle.

[0192] Fig. 10A and 10B is a front view depicting a docking alignment between the automated guided vehicle 712 and one of the FAMs 918 according to some embodiments, but this is activated (in Fig. 10A and 10B In the illustrative embodiment of FIG. 1 , the first drive system includes gears 720 a and 720 b. In order to maintain the FAM 918 in a position similar to, for example, Fig. 9 The mobile rack structure depicted is aligned with the position and Fig. 10B As best seen in FIG. 1 , one or more embodiments of FAM 918 include upper and lower docking clamps, indicated generally at 927a and 927b, respectively. When FAM 918 has been aligned with the rack structure, it is lowered into position by carrier 712, which engages the docking clamps with corresponding clamps secured to or otherwise formed on the mobile rack structure.

[0193] Fig. 10C is from Fig. 10A918, and depicts the alignment of the rotating element of the first drive system (e.g., gearwheel 720b) ​​with the corresponding part of the guide system of FAM 918. In the example case, the guide system of the functional attachment module 918 includes an inward track, such as track 926. Once the carrier 712 has entered the interior space defined between the vertical columns 929 of FAM918, the gearwheel of the carrier rotates so that the drive system wheel engages with the guide system of FAM 918 (in this example) including inward track pairs 926, which engage with gearwheels 720a and 720b. In the case of unidirectional rotation, FAM 918 is lifted above the bottom support surface, and the FAM can be transported by the carrier 712. Once in the aligned position, the gearwheel of the carrier 712 rotates in the opposite direction to lower FAM 918, such as back on the bottom support surface. In the process, the aforementioned docking clamps 927a and 927b are engaged. FIG. 10C to FIG. 10E Vehicle 712 is depicted lifting FAM 918 for transport.

[0194] See Fig. 10A and 10B It will be appreciated that the process by which a carrier consistent with the present disclosure (e.g., carrier 712) is aligned with and enters a FAM (e.g., FAM 918) may be performed regardless of whether FAM 918 is already engaged in the process of delivering items to a destination area. In fact, an advantageous feature of some embodiments consistent with the present disclosure is that each carrier is configured to complete some or all of the assigned inventory management tasks according to the first operating mode without the use of an accessory module, such as from, for example Figure 1C , transferring an item C from one storage area 110 to a different storage area 110, delivering an item (e.g., container C) to a picking station, or any combination of these. Fig. 9 and 10A -12, the same vehicle is also configured to perform other tasks according to the second operating mode by acquiring and utilizing a single or multiple FAMs to perform one or more additional inventory management tasks. For example, Figures 10C to 10E The carrier 712 configured according to the second operating mode is shown entering the FAM 918 while carrying a container to lift the FAM, to shift the FAM 918 horizontally to a different position, and to lower the FAM at the different position. Fig.10F As shown, vehicle 712 is further configured to ascend within FAM 918 in order to facilitate inventory management tasks.

[0195] Fig. 10D According to one or more embodiments, Fig. 10A and 10CAn enlarged partial front view from the same perspective after actuating corresponding rotating elements (e.g., large gears 720a and 720b) ​​of the first drive system of the carrier 712 in the first direction using the corresponding facing track portion 926 of the guide system of the functional accessory module 918, wherein the guide system is used to lift the FAM module 918 above the surface in the manner shown in 10D. Fig. 10E According to one or more embodiments, Fig. 10B The same viewing angle shows a front view after actuating the rotary element of the first drive system in the first direction with a corresponding counter-part of the guide system of the functional attachment module for lifting the functional attachment module. Fig.10F According to one or more embodiments, Fig. 10B and 10E The same perspective shows a front view after actuating the corresponding rotating element of the first drive system of the carrier in the second direction with the corresponding facing part 926 of the guide system of the functional accessory module, wherein the guide system is used to place the functional accessory module on the underlying support surface and subsequently lift the carrier 712 within the functional accessory module 918 as shown.

[0196] Fig.11A is a diagram depicting a method of, for example, Figures 10A to 10F A rear perspective view of an exemplary FAM 918 or similar functional accessory module depicted in FIG. 1 deployed to a mobile rack structure 1120 that is sized and arranged to supply items such as fast-moving merchandise (not shown) in an inventory management system 1100. Figures 10A to 10F Recall that a dynamically deployable FAM, such as FAM 918, may include one or more docking or retaining clamps, such as upper and lower docking clamps generally indicated at 927a and 927b, respectively. Fig. 11B According to one or more embodiments, the functional accessory module 918 is immediately before docking with the mobile rack structure 1120. Fig. 11B In this example, the mobile rack structure 1120 includes a pair of corresponding upper and lower docking clamps, indicated generally at 1027a and 1027b, wherein these are sized and arranged to receive and retain a portion of the clamps 927a and 927b.

[0197] To bring the corresponding pairs of upper and lower docking fixtures into interlocking alignment, the first and / or second drive systems of the carrier 712 are operated to move the FAM 918 in the direction of the horizontal arrow. Fig.11A), drives the large gear of carrier 712 in a direction opposite to the direction required to lift FAM 918, during which time FAM 918 moves in the direction of the vertical arrow. This rotation continues until the surface of FAM 918 is supported by the underlying support surface. The resulting interlocking between the complementary pairs of docking clamps secures FAM 918 against the flow rack structure 720. Fig.11A It should be kept in mind that other mechanisms may be employed to revocably interlock the FAM 918 and the shelf structure 1120 without departing from the spirit and scope of the present disclosure.

[0198] In some embodiments and as previously described, the structure that performs the functions of the FAM 918 may be integrally formed with a portion of the shelf structure 1120 or attached to the shelf structure 1120 using fasteners, clamps, etc., such that coupling / uncoupling and separation are not performed by coordinated movement of the carrier 712. Suffice it to say that any such shelf structure need only define a mission activity area that a carrier (e.g., carrier 712) may enter, climb, align with a storage surface, and perform item exchanges between the surface of the shelf structure and the carrier's transfer platform.

[0199] In any case, and now go to Fig. 11C , showing after the FAM 918 is docked with the mobile rack structure 1120 and the vehicle 712 is lifted in the mission activity area Z Fig.11A and 11B As depicted, the illustrative rack structure includes three levels of storage locations, generally indicated as 1102, 1104, or 1106, respectively. The carrier 712 is shown as having reached a vertical elevation within the mission activity zone Z of the FAM 918 aligned with the uppermost storage level 1106, and the rollers 711 of the carrier transfer mechanism have been activated to propel the container C onto the target surface of the rack structure 1120.

[0200] In some embodiments consistent with the present disclosure, for example, Figures 2A to 2I. In one such embodiment, a first onboard motor is used to independently rotate one of the central drive elements (e.g., drive element 752b), while a second onboard motor is used to independently rotate the other of the central drive elements. In this embodiment, rotation in either direction is achieved by rotating the central drive elements in opposite directions or in the same direction (but one faster than the other) for a larger turning radius. In addition, the omnidirectional wheels on one side (e.g., wheels 754b and 756b) can be driven by the same onboard motor used to drive the central drive elements on that side. By way of another example, a single third onboard motor can be used to drive all of the omnidirectional wheels, as previously described in conjunction with vehicle 200. In any of the above examples and other examples, the transfer mechanism can be driven by yet another onboard motor, thereby avoiding the need for a clutch mechanism.

[0201] In one or more other embodiments of the inventory management system 1100, the vehicle 712 incorporates a second drive system ( Figures 3A to 4C ) and transfer agencies ( Figures 2D to 2I ) feature. In such embodiments, the onboard motor (not shown) of the carrier 712 is operated to cause the carrier 712 to climb within the activity zone Z. In this example, the large gear of the carrier 712 rotates against the teeth of the track 926. As a result, the front omnidirectional wheels (e.g., wheel 754b) and the rear omnidirectional wheels (e.g., wheel 756b) leave their respective positions supported on the underlying support surface. In addition, the pivotable carrier (not shown) discards the second drive element, only the second drive element 752b is shown, and one or more clutch mechanisms (not shown) are engaged at the same time. The engagement of the clutch mechanism then enables the rotation of the sprocket 717b. The rotation of the one or more additional motors drives the endless carrier 714b and causes the transfer mechanism to advance the container C onto the surface 1106 of the storage structure 1120.

[0202] Continue to view Fig. 11C It should be noted that if the pitch angle of the storage level is sufficient, it is possible for the container C to be propelled solely by gravity, for example in a passive roller or chute configuration. Figures 11D to 11G In the illustrated embodiment, the multi-level shelf structure 1120 of the inventory management system 1100 includes unloading assistance at each level. In some embodiments, and as already combined Fig. 9 As depicted, the unloading aid includes a plurality of parallel belts 1128 and optional sensors for determining timing for advancing inventory items stored by a carrier (eg, carrier 712) toward an end closest to the picker.

[0203] Fig.11D According to one or more embodiments Figures 11A to 11CA front perspective view of an illustrative embodiment depicting the carrier 712 within the functional accessory module 918 raised to Fig. 11C In the location shown in . Fig.11E is in line with Figures 11A to 11D 100 , depicting the elevation of a vehicle 712 within a mission activity area within a functional attachment module 918 . Fig.11F During the transfer of container C1 from the transport platform of the lifted carrier 712 to the target surface 1106f of the shelf structure 1120 according to one or more embodiments. Figures 11A to 11E An enlarged partial top plan view of an illustrative embodiment.

[0204] As an illustrative example, according to an e-commerce application, the inventory management system 1100 is deployed in an order fulfillment facility. Carriers 712 are supplied with containers such as containers C1 and C2, which may contain multiple individual inventory items. In this example, the warehouse management system (WMS) of the facility has determined that a sufficient amount of the entire I will be needed during the current or upcoming inventory management interval. S1 ,I S2 ,I S3 ,I S4 ,I S5 and I S6 A subset of the inventory items indicated is then removed to justify their continued placement in the shelf structure 1120. In an embodiment, the dynamic placement of inventory items using carriers and FAMs (e.g., FAM 918) reduces the time required to extract items so that they can be packaged for shipment as part of an e-commerce operation. As an illustrative example, a human operator moves between a packaging station and an item transfer area A adjacent to the shelf structure 1120, which isolates it from the carrier 712 operating in the item transfer area B.

[0205] See also Fig.11E and 11F , it will be seen that vehicle 712 has interrupted its ascent within the mission management area of ​​FAM 918a and has stopped at the position indicated as a whole by 1106a to 1106g (which is in Fig. 11C and 11D The transfer locations are associated with multiple third-layer locations (also collectively identified as numeral 1106).

[0206] At least some subset of the items, such as subset I, may continue to be required in sufficient quantities during a current or upcoming inventory management interval compared to other items handled by the facility. s1 To I s5, and the contents of container C1 and those containers in storage area 1100g, to the flow rack structure 1120. In this example, the WMS has determined that other items stored in the rack structure 1120 - such as those stored at location 1106f in container C2 for retrieval during an earlier phase of the current inventory management interval (and / or during a previous inventory management interval) - no longer have sufficient priority to be present in the same quantity in the rack structure 1120, or have no priority to be present in the rack structure 1120 at all. In embodiments consistent with the present disclosure, the same carrier 712 and FAM 918a or a different carrier-FAM pair may be used to replace container C2 with a different container. See also Figures 11G to 11I An exemplary sequence of such replacement operations is described.

[0207] Fig.11G It is a depiction Figures 11A to 11F , which depicts FAM 918a temporarily deployed into a position of interlocking alignment with storage location 1106f of shelf structure 1120. While in this position, carrier 712a is raised within the mission activity area of ​​FAM 918a to extract container C2 in the manner previously described, and then carrier 712a is returned to the underlying surface. Further operation of the large gear causes FAM 918a to be lifted from the underlying support surface, and carrier 712a repositions FAM 918a to Fig.11G The solid line position shown in . Fig.11G In the illustrative embodiment of FIG. , the movement of the carrier 712a and Fig.11G The movement of the vehicles 712b to 712d shown in FIG. 1 is guided by a grid of fiducial markers indicated at 1132, which are sensed by one or more imaging sensors (e.g., cameras) of each vehicle (not shown). However, it should be understood that other position tracking systems and techniques may be utilized without departing from the spirit and scope of the present disclosure.

[0208] In one or more embodiments, the vehicle 712a utilizes capacitors that must be periodically charged. In some embodiments, the vehicle returns to a charging station that is remote from the rack structure 1120, while in other charging stations, the charging port (not shown) is in situ, near the track structure, so that the vehicle 712a does not need to exit the mission activity area of ​​the FAM 918a. Fig.11H and 11I 1 is a rear elevation view of the shelf structure 1120 of the inventory management system 1100 after the transfer of item C2 from carrier 712a to carrier 712b described above. In this example, carriers 712a and 712b have each returned to a charging station to restore power before assigning additional inventory management tasks. Thus, Fig.11H Depicting vehicle 712c has entered FAM 918a, and Fig.11IThe carrier 712c has lifted the item C3 in the task management area of ​​the FAM 918a, and then the transfer mechanism of the carrier 712c has been operated to transfer the item C3 to the storage area 1106e ( Fig.11G ) transfer.

[0209] Fig.12 is a diagram that can be formed according to one or more embodiments Figure 1C 1200 that utilizes autonomous vehicles 1212 to transfer containers 1202 of inventory items between a picking area and a vertical array of storage locations indicated generally at 1220. In this example, the material handling system incorporates Fig. 9 1200, but further utilizes the carrier 1212 and the array of storage locations 1120 as elements of an automated storage and retrieval system (AS / RS). The carrier 1212 may be configured in the same manner as the previous carriers 200 and 712 in order to utilize the dynamically deployable FAM structures 718a and 718b alongside the structure defining the vertical array of storage locations 1220. However, it should be kept in mind that where such compatibility is not required, such as in the case of embodiments that rely on mobile rack structures 1120 and storage locations 1220, those features of the carrier that are guided to maintain maneuverability under heavier loads need not be incorporated.

[0210] In any case, and now go to Figures 13A to 13E , the storage locations (e.g. Fig.12 The storage and retrieval process of items in the array at position 1220). First go to Fig.13A , shows a front elevation view depicting a plurality of automated guided vehicles 1212a through 1212e operating within or about a shelf structure 1300. As in previously described embodiments, the vehicles perform various item replenishment and / or item retrieval tasks, and in this example, some of those tasks involve retrieving containers from or returning containers (or totes) to storage locations 1315a, 1315b, 1315c, and 1315d.

[0211] like Fig.13A and 13B As seen in FIG. 1 , carriers 1212b and 1212d are depicted as being supported by the underlying support surface as they are maneuvered within zones Z1 and Z2 directly below the storage location. In an embodiment, zones Z1 and Z2 are maneuvering zones that allow carriers to be conveniently moved into or out of the shelf structure 1300. For example, in FIG. Fig.13A13, carrier 1212a is seen entering structure 1300 and passing under support surface 1322 of the first vertical array of storage positions. In this example, support surfaces 1320 and 1322 are defined by shelf pathways supported by a plurality of vertical support columns. Fig.13A , support columns 1304a, 1306a, 1308a, and 1310a are depicted therein. Vehicle 1212b is shown as having performed a 90 to 270 degree turn in order to continue traveling on the generally horizontal support surface below transfer zone Z1. On the other hand, vehicle 1212c has entered the row in which it will rise. In an embodiment, vehicle 1212c rises in the same manner as vehicle 1212e, which is shown as having risen within a drive column behind the drive column occupied by vehicle 1212c. More specifically, each of vehicles 1212a and 1212e is moved within its respective drive column by actuation of a drive system, which, as in the previous embodiments, may include a large gear having teeth for engaging complementary teeth defined by inward track segments formed along the four support columns. Vehicle 1212d is shown traveling along the support surface of the underlying zone Z2, having either entered zone Z2 from a location external to structure 1300 or is now ready to exit.

[0212] Fig. 13B is a diagram illustrating a transport box T according to one or more embodiments. a 、T b 、T c and T d A side elevation view of a rack structure 1300 filled with a plurality of containers or totes, with a plurality of carriers used as, for example, Fig.12 A portion of the inventory management system 1200 of the present invention performs various item replenishment and / or item retrieval tasks. Here, again, the tote 1212a is shown as having passed through the transfer zone Z1 into the leftmost drive column indicated at D1. In this regard, and now referring to Fig. 13C It will be appreciated that the structure 1300 may incorporate an array of parallel rails, such as rails R1 and R2, defining a gap g therebetween. G The gaps are sized and arranged to receive corresponding alignment structures on the carriers to enable entry, exit, and reorientation of the carriers without causing damage to each other and the shelf structure. Such structures have been described in conjunction with carrier 200, and such details are omitted herein for clarity and convenience of description. It is sufficient to say that where such structures are present on the carrier, additional alignment structures incorporating one or more gaps may be included to guide the carrier. For example, Fig. 13CAs seen in FIG. 1 , the second floor mounted alignment system 1350 incorporates a circular plate-like component having an intersecting gap pattern. In this example, it can be seen that the carrier 1212b uses the alignment system 1250 to angularly reorient itself, such as to prepare for a right turn in travel within zone Z2.

[0213] As yet another exemplary alignment structure, embodiments consistent with the present disclosure may include a third floor mounted alignment system 1340 that is separated by a gap g. G In this example, the gaps defined by alignment system 1340 are oriented relative to those defined by alignment system 1350 so as to allow the carrier to quickly and easily traverse the entire width of the structure - from zone Z1 to zone Z2, but prevent angular reorientation within drive columns D1 to D6.

[0214] As mentioned above, the structure 1300 is sized and arranged so that the carriers can enter and exit from various locations below the storage location, thereby allowing flexibility in the installation of the picking and / or replenishment station. Fig.13D and 13E , the shelf structure 1300 may be provided with support columns (e.g. Fig.13A The support columns 1304, 1306a, 1308a and 1310a) have a network of support portions (indicated generally at 1370) of reduced cross-section. In some embodiments, the support members 1370 of reduced cross-section are telescopically received and attached at desired locations by fasteners, welding, etc.

[0215] In one or more embodiments, the retractable guide wheels may be omitted so that the carrier is not damaged. Fig.13E , it will be observed that the guide system 1380 of the rack structure 1320 includes a specially configured (relaxed tolerance) transition zone, indicated generally at 1380a. The guide system 1380, including the transition zone 1380a, is mounted on opposite sides of the support 1370, but not on the other two sides. In the transition zone, gaps are formed between the teeth of the track so that the teeth of the carrier gearwheel can pass freely without damage. This guide system arrangement enables a carrier to be driven directly into a drive column without first having to reduce the spacing between the guide wheels 1320a and 1320b, but it also enables a carrier to move up and down within an immediately adjacent column, such as Fig. 13B Best in Show.

[0216] Fig.14A1 is a schematic block diagram depicting the distribution of FAM-assisted inventory management tasks among a plurality of vehicles by a controller, generally indicated by reference numeral 1450. The controller 1450 organizes a plurality of automated guided vehicles into respective groups of one or more vehicles. The first of the vehicle groups indicated at 1402-1 through 1402-n does not have a FAM association. As will be seen in Figures 1A to 1C , Fig. 9 and Fig.12 Recall that not all tasks require the use of a FAM. Further, after the FAM association has been terminated, the vehicle may return to the charging station and be ineligible to receive inventory management task assignments from the controller 1450 during this time. The second of the vehicle groups, indicated generally at 1404-1 through 1404-n, may be associated with a FAM selected from a first category or group of FAMs and a second category or group of FAMs. By way of example, FAM Category 1 may include an auxiliary adapter (such as FAM 714 described previously), while FAM Category 2 may include a shiftable shelf FAM indicated at 718. The third of the vehicle groups, indicated generally at 1406-1 through 1406-n, may include a bin of auxiliary FAMs 614 and transport FAMs 618. The fourth of the vehicle groups, indicated at 1408-1 through 1408-2, may include a FAM 918 for allocating inventory to (and optionally from) mobile shelf modules, such as Fig. 9 Finally, controller 1450 also tracks the location of any FAM that is not currently assigned.

[0217] Fig. 14B 1 is a block diagram depicting subsystems of a plurality of guided vehicles 1412-1 through 1412-n according to one or more embodiments. Each vehicle (e.g., vehicle 1412-1) includes a controller including a central processing unit (CPU) 103, a memory 105, and a communication interface 1407. In some embodiments, the communication interface includes one or more wireless transceivers compliant with a corresponding wireless transmission protocol such as IEEE 802.11, wherein the vehicle's interface is used to communicate with other vehicles, such as in a peer-to-peer topology, or with a central controller. In the latter aspect, the vehicles 1412-1 through 1412-n may include position sensors indicated at 1413 and object sensors 1415, and use the interface to communicate with, for example, Fig.14A The sensed information is communicated to a master controller such as controller 1450 of the controller. In one or more embodiments, the position sensor includes an onboard imaging sensor for determining when a vehicle has passed over a fiducial marker positioned on an underlying support surface. Alternatively, however, vehicles 1412-1 to 1412-n may utilize signal triangulation and / or any other conventional technique to determine their corresponding positions relative to each other or enable a controller to determine their corresponding positions relative to each other.

[0218] Continue to view Fig. 14B , it will be seen that each AGV (e.g., AGV 1412-1) includes a power supply 1417, which may be, for example, a rechargeable power supply including an ultracapacitor, one or more batteries, or a combination of these. In one or more embodiments, the power supply drives a first motor 1419 of a first drive system 1409. The first drive system 1409 may further include a large gear that is driven by the first motor and is used, for example, to drive a carrier vertically within a FAM (e.g., FAM 918) or within an AS / RS rack structure 1320. In this example, the power supply 1417 also supplies power to a second drive system 1411, which includes a second motor 1421 and an optional third motor 1423.

[0219] The CPU 1403 may include one or more commercially available microprocessors or microcontrollers that facilitate data processing and storage. Various support circuits facilitate the operation of the CPU 1403 and include one or more clock circuits, power supplies, caches, input / output circuits, etc. The memory 1405 includes at least one of a read-only memory (ROM), a random access memory (RAM), a disk drive storage device, an optical storage device, a removable storage device, etc.

[0220] Fig. 14C 1 is a schematic block diagram of a controller 1450 that can coordinate the assignment and execution of inventory management task activities (e.g., inventory management task activities assigned to AGV task groups 1402-1, 1404-1, 1406-1, and 1408-1) of multiple carriers and FAMs in response to instructions received from a warehouse automation system (WMS) 1440. The controller 1450 includes a central processing unit (CPU) 1451, support circuits 1455, memory 1452, user interface components 1454 (which may include, for example, a display with a touch-sensitive screen or a separate keyboard), and a communication interface 1453. In some embodiments, the server 1450 includes one or more wireless transceivers that comply with corresponding wireless transmission protocols such as IEEE802.11.

[0221] The CPU 1451 may include one or more commercially available microprocessors or microcontrollers that facilitate data processing and storage. Various support circuits 1455 facilitate the operation of the CPU 1451 and include one or more clock circuits, power supplies, caches, input / output circuits, etc. The memory 1452 includes at least one of a read-only memory (ROM), a random access memory (RAM), a disk drive storage device, an optical storage device, a removable storage device, etc. In some embodiments, the memory 1452 includes an operating system 1456 and one or more inventory management applications. In some embodiments, the inventory management application includes a task agent manager module 1460, an AGV traffic management module 1470, a status / event monitoring module 1480, and a data repository 1490.

[0222] In one or more embodiments, the task agent manager 1460 is configured with an inventory management task processor 1461, a dynamic inventory placement analyzer 1462, a subtask sequence identifier 1463, a task priority manager 1464, an event notification detector 1465, a state transition detector 1466, an AGV selector 1467, and a FAM selector 1468. The inventory management task processor 1461 processes the inventory management task request received from the WMS 14440 by executing instructions by the CPU 1451. The list of subtasks associated with the received task request includes, for example, those listed in the following table:

[0223]

[0224] In one or more embodiments, the dynamic inventory placement analyzer 1462 allocates inventory items between different storage areas based on available human resources, the distance between where those resources are located and the corresponding storage location pool, and the known or predicted item demand within the current and at least one subsequent inventory management interval (e.g., 60 to 120 minutes). The subtask sequence identifier allocates the subtasks comprising each inventory management task between one or more vehicles and FAMs. By way of example, a first AGV may lack sufficient power resources to complete all subtask elements of the entire task. In this case, the first AGV may be directed by the controller to transfer inventory items and / or FAMs to a second AGV, with timing sufficient to enable the first AGV to return to the charging station and recharge before returning to the pool of AGVs with mission qualifications. To facilitate this functionality, the task agent manager 1460 further includes an event notification detector 1465 to determine when a critical power level threshold has been exceeded, and a state transition notification detector 1466 to determine when other AGVs and FAM assets have returned to a mission-qualified state.

[0225] AGV and FAM selectors 1467 and 1468 respectively utilize the available position, power, and remaining subtask data to select the appropriate utilization of AGV and FAM resources to complete any subtasks that have not yet been completed by another AGV, and ensure that tasks are assigned to those AGVs and FAMs that have the resources to complete them when possible. The AGV and FAM selectors may rely on information received from the position analyzer 1475 and the priority monitor 1476.

[0226] In some embodiments, traffic management for the AGV is performed by a traffic management module 1470 of the controller 1450. In such cases, position, speed, and direction data are collected from the vehicles by the controller at regular intervals. The position data is analyzed, and a segment selector 1474 selects a path for each vehicle within the next control interval to ensure that there is no collision with other vehicles, with workers, or with fixed structures. Updated instructions corresponding to the path selection (including heading and direction) are transmitted back to the vehicle by the controller. However, in other embodiments, the vehicle does not rely on the controller to obtain relative positioning instructions, but is only used to obtain destinations and task assignments, where the vehicle actually relies on internal data collection and spatial analysis capabilities.

[0227] To facilitate the aforementioned operations, Fig. 14C The controller 1450 contains a data repository reflecting the latest location of all inventory items for which management and assigned responsibilities have been assigned by the WMS, as well as a map of the locations of the FAMs within the facility. In addition, to facilitate scheduling preventive maintenance procedures, usage statistics are collected for all AGVs and FAMs that have moving parts so that parts can be inspected, lubricated, and / or replaced at regular intervals.

[0228] It will therefore be appreciated from the above description that in some embodiments, a first type of shelf structure in which a carrier is configured to operate according to a first operating mode defines a plurality of vertical arrays of storage locations separated by aisles of rows in which the carrier climbs. Such a shelf structure is comprised of Figures 13A to 13E An embodiment is exemplified in which the guide system includes parallel tracks that are sized and arranged so that a carrier can enter a climbing row not from the end of the corresponding aisle in which the row is located, but from the side of the row. That is, the carrier is configured to move on the portion of the support surface that is directly below the storage position of the array so that it can enter any climbing row from a direction transverse to the longitudinal axis of the aisle of the climbing row. Thus, two or more carriers can enter and / or leave corresponding climbing rows of the same aisle at the same time.

[0229] In some embodiments, the depth of the space allocated to the storage position and therefore to the path along the underlying support surface on which the vehicles travel to enter and exit the climbing column is of sufficient length to enable two vehicles to turn and travel along paths that are parallel to each other (whether in the same or opposite directions).

[0230] In some embodiments, the carrier is configured such that a second type of shelf structure operating in accordance with the first operating mode defines a plurality of feed flow surfaces supplied by aisles of climbing rows along which parallel tracks of the guide system are arranged vertically. Figures 11A-11H Such embodiments are exemplified. In one such embodiment, the feed flow surface is defined by a plurality of non-driven rollers that are sized and arranged to feed inventory items unidirectionally by means of gravity as the inventory items are received from a carrier within one of the climbing trains. Additionally or alternatively, at least some of the feed flow surfaces are defined by a plurality of driven rollers that are configured to propel items in a first direction off a carrier within one of the climbing trains for retrieval by one or more fulfillment station operators, and to propel items in a second direction opposite the first direction for transfer of the items to a carrier in the climbing train during a replenishment operation. In an alternative example, the feed flow surface may be defined by a plurality of horizontally oriented belts driven in first and second directions to accomplish the same retrieval and replenishment functionality as the previously described drive rollers. Although Figures 11A to 11H The climbing columns in the case of are depicted as being displaceable vertically and horizontally by the vehicle according to the second operating mode, but in other embodiments consistent with the present disclosure, these climbing columns are fixed.

[0231] Fig.15 1 is a flow chart depicting a process 1500 by which inventory management tasks may be assigned to one or more vehicles and FAMs. The process 1500 is entered at 1502 and proceeds to 1504, where an inventory management task request is received. The process 1500 proceeds to 1506, where the process identifies a sequence of subtasks applicable to the task requested at 1504. From 1506, the process 1500 proceeds to 1508, where the process determines which AGV and FAM resources are needed to complete one or more of the subtasks identified at 1506. From 1508, the process 1500 proceeds to 1510, where the process determines the time and power requirements for completing the one or more subtasks identified at 1508. The process 1500 proceeds to decision box 1512.

[0232] At decision box 1512, the process determines whether there are any currently pending tasks with a higher priority than the task request received at 1504. If not, the process proceeds to decision box 1514, where the process determines whether the required AGV and FAM resources are available for assignment to the task request specified at 1504. If not, the process returns to decision box 1512, but if yes, the process proceeds to 1516 and the process establishes a new task association between the AGV and one or more FAMs. From 1516, the process proceeds to 1518, where the process transmits the instruction to the AGV identified at 1514. The process proceeds to decision box 1520. At decision box 1520, the process determines whether all assigned subtasks have been completed. If not, the process returns to 1508 to allocate additional resources. If yes, the process proceeds to 1522 and determines whether the inventory management loop is still active and open, and if so, the process returns to 1504. If no, the process proceeds to 1524 and terminates.

[0233] In the case where the process 1500 determines at 1512 that a higher priority task is pending, then the process proceeds to 1526 and assigns a priority to the task request received at 1504, and the process proceeds to 1528. At 1528, the process assigns the current task sequence to a task queue. In this regard, it should be noted that there may be many such task queues. Among the tasks remaining in the assigned task queue, the process determines which one has the current highest priority, and the process returns to decision block 1512.

[0234] Fig.16 1 is a flowchart depicting a process 1600 by which inventory items can be dynamically allocated between various storage areas within a series of continuous inventory management intervals according to one or more embodiments consistent with the present disclosure. The process 1600 enters at the start box 1602 and proceeds to 1604, where a dynamic delivery interval counter is initialized. In some embodiments, the facility can operate for two 8-hour shifts or 16 hours. In this example, a one-hour delivery interval is used, so that the process proceeds to 1606 and increments by 1 to represent each delivery interval. At 1606, the received inventory management tasks scheduled to be completed during the current or approaching delivery interval are analyzed, and it is determined which inventory items should be placed in a first storage area reserved for faster moving goods, and which can be relocated to a second storage area suitable for slower moving goods. The process assigns the inventory items of the first subset to the first storage area, and the inventory items of the second subset to the second storage area. The process proceeds to 1608.

[0235] At 1608, the process 1600 starts operation of a first group of AGVs to begin relocating a first subset of inventory items from the second storage area to the first storage area, and at 1610, starts operation of a second group of AGVs to begin relocating a second subset of inventory items from the first storage area to the second storage area. The process proceeds from 1610 to 1612. At 1612, the process operates a plurality of AGVs to transfer at least some inventory items from at least the first of the relocated first subset of inventory items to a destination area. The process proceeds from 1612 to 1614, where the process operates a plurality of FAMs and AGVs to transfer inventory items from at least the first of the relocated subset of inventory items to the destination area. The process proceeds to 1616.

[0236] At 1616, the process increments the dynamic delivery interval counter and proceeds to 1618 to determine if there are any remaining increment cycles in the current inventory management cycle. If so, the process returns to 1606 and performs analysis for subsequent delivery windows. If not, the process proceeds from decision block 1618 to termination block 1620 and ends.

[0237] Fig.17 1 is a flow chart depicting a process 1700 according to one or more embodiments consistent with the present disclosure. A controller of an automated guided vehicle performing process 1700 operates the vehicle to perform an inventory management task using only onboard resources and capabilities of the vehicle according to a first operating mode and additionally using resources and capabilities of one or more FAMs according to a second operating mode. Process 1700 is entered at 1702 and proceeds to 1704, where the method 1700 determines an operating mode required to perform the inventory management task. Process 1700 proceeds to 1708, where the process identifies whether the first operating mode is applicable, and if so, process 1700 proceeds to 1710.

[0238] At 1710, in accordance with a first mode of operation of the carrier, method 1700 controls rotation of a first plurality of drive elements of a second drive system of the carrier, and proceeds to 1712, where method 1700 aligns the first plurality of drive elements of the first drive system with a guide system disposed along an array of storage locations of the shelf structure. From 1712, method 1700 proceeds to 1714, where method 1700 controls rotation of the second plurality of drive elements of the first drive system to vertically displace the carrier to reach one of the storage locations, or alternatively leave one of the storage locations. Regardless of whether method 1700 is performing a task whereby an item is retrieved from a storage location of the shelf structure rather than to the storage location, method 1700 performs 1710 to 1712 twice—a first time to first enter the shelf structure and reach a target storage location to operate the carrier's onboard transfer mechanism to retrieve or deposit the item, and a second time to reverse the order to leave the target storage location and exit the shelf structure.

[0239] In some embodiments, method 1700 is performed using a carrier in which the first plurality of drive elements of the first drive system are maintained at a fixed distance from each other corresponding to the spacing between the parallel tracks of the guide system, and this configuration is not required for the performance of method 1700. In an alternative embodiment consistent with the present disclosure, for example, the alignment of 1712 can be achieved by performing additional steps, the additional steps being: using an additional drive mechanism to move the first plurality of drive elements of the first drive system toward each other and then into an opening defined in the shelf structure aligned with the parallel tracks, and then moving the first plurality of drive elements of the first drive system away from each other to bring the corresponding engagement surfaces into a position where the rotation of the first plurality of drive elements begins the vertical displacement of 1714.

[0240] In any case, continue to see Fig.17 , process 1700 proceeds from 1714 to decision box 1716, whereupon process 1700 determines whether additional tasks remain, and if so, the process returns to 1704. Method 1700 is additionally and alternatively configured to proceed from 1708 to 1720, where, according to a second operating mode, method 1700 controls rotation of the first plurality of drive elements of the second drive system to cause the carrier to enter or exit an opening defined by an accessory module. Method 1700 proceeds from 1720 to 1722, where the method controls rotation of the first plurality of drive elements of the second drive system to displace the carrier and accessory module horizontally. Method 1700 proceeds from 1722 to 1724, where the method controls rotation of the first plurality of drive elements of the first drive system to displace the accessory module vertically.

[0241] It should be kept in mind that the order in which 1720 through 1722 are performed depends on the specific task assigned. For example, the transfer of an accessory module from one location in the inventory management facility to another location is accomplished by performing 1724 a first time after the carrier enters the accessory module at the first location before performing step 1722. Once method 1700 performs 1724 to lift the carrier at the first location, step 1722 is performed to reposition the lifted accessory module. 1724 is then performed again at the second or target location to lower the accessory module onto the underlying support surface, and step 1720 is performed again to remove the carrier from the accessory module.

[0242] In some embodiments, such as where a first accessory module acts as an adapter to lift a second accessory module, steps 1720 to 1724 are performed by method 1700 to extract and reposition the first accessory module to the location of the second accessory module, and then steps 1720 and 1724 are re-performed by the carrier to enter, lift, and horizontally shift the second accessory module.

[0243] Although the present invention has been described and illustrated largely in the context of the movement of inventory in a warehouse, fulfillment center, or distribution center, it should also be understood that the present invention is directed to the transportation of other types of objects, as well as various uses including the aggregation of parts in manufacturing operations, etc. In addition, for the purpose of illustration, the above description has been described with reference to specific embodiments. However, the above illustrative discussion is not intended to be exhaustive or to limit the invention to the precise form disclosed. In view of the above teachings, many modifications and variations are possible. The embodiments are selected and described in order to best illustrate the principles of the present disclosure and its practical application, thereby enabling others skilled in the art to best utilize the present invention and various embodiments with various modifications suitable for the particular use contemplated.

[0244] The order of the methods described herein may be changed, and individual elements may be added, reordered, combined, omitted, modified, etc. All examples described herein are presented in a non-limiting manner. It is obvious to those skilled in the art who benefit from the present disclosure that various modifications and changes may be made. The implementation forms according to the embodiments have been described in the context of specific embodiments. These embodiments are intended to be illustrative, not restrictive. Many changes, modifications, additions, and improvements are possible. Therefore, multiple instances may be provided for the components described herein as single instances. The boundaries between the individual components, operations, and data storage areas are arbitrary to some extent, and specific operations are described in the context of specific illustrative configurations. Other functional allocations are envisioned, and they may fall within the scope of the appended claims. Finally, the structures and functionality presented as discrete components in the example configuration may be implemented as combined structures or components. These and other changes, modifications, additions, and improvements may fall within the scope of the embodiments defined by the appended claims.

[0245] Therefore, while the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope of the invention is determined by the appended claims.

Claims

1. A vehicle configured to perform inventory management tasks in an inventory management handling system having multiple destination areas and a guidance system, the vehicle comprising: a platform sized and arranged to receive items to be at least one of transferred to one of the destination areas or received from one of the destination areas; Multiple motors; a first drive system having a first plurality of drive elements configured to engage the guidance system via operation of a first subset of the plurality of motors to move the vehicle along a vertical segment extending between a support surface beneath the vehicle and one of the destination areas; a second drive system having a second plurality of drive elements configured to engage an underlying support surface and drive movement of the vehicle in a non-vertical direction through operation of a second subset of the plurality of motors; a transfer mechanism configured to perform at least one of transferring an item from the platform to one of the plurality of destination areas or extracting an item from one of the plurality of destination areas; as well as a clutch mechanism configured to engage and disengage the transfer mechanism from the second subset of motors, whereby the second drive system drives movement of the carrier independently of the transfer mechanism; wherein the second drive system comprises a first drive element driven by a first motor of the second subset to rotate about a first rotation axis, and a second drive element driven by a second motor of the second subset to rotate about a second rotation axis, wherein each of the first drive element and the second drive element is sized and arranged to engage a respective portion of the underlying support surface to effect movement of the carrier thereon; The clutch mechanism comprises: a first pivotable carrier movable between a first angular orientation relative to the platform and a second angular orientation relative to the platform, wherein the first drive element is rotatably coupled to the first pivotable carrier for angular movement therewith; A second pivotable carrier is movable between the first angular orientation and the second angular orientation, wherein the second drive element is coupled to the second pivotable carrier for angular movement therewith. 2 . The vehicle of claim 1 , wherein the first subset comprises a single motor configured to rotate the first plurality of drive elements of the first drive system.

3. A vehicle according to claim 1, wherein the first plurality of drive elements of the first drive system include a plurality of gears, which are sized and arranged to interact with complementary teeth of the guide system to control the position of the vehicle along the guide system.

4. The vehicle of claim 3, wherein the first drive system further comprises a pair of drive axles, wherein driven gears are fixed to the drive axles such that the gears are driven synchronously to drive the vehicle along the guide system.

5. The carrier of claim 1 wherein the first and second axes of rotation are coaxial with the first and second pivotable carriers having a common angular orientation.

6. The vehicle of claim 1, wherein the second drive system further comprises: a first driven element rotatably coupled to the first pivotable carrier, and a first endless loop element for transferring rotational power to the first driven element; and A second driven element rotatably coupled to the second pivotable carrier, and a second endless loop element for transferring rotational power to the second driven element.

7. The carrier of claim 6, wherein each of the first endless loop element and the second endless loop element is a belt.

8. The vehicle of claim 6, wherein the second drive system further comprises: a first pulley, the first pulley and first drive element being driven by the first motor of the second subset, wherein the first pulley is sized and arranged to engage the first endless loop element to thereby drive the first driven element; as well as and a second pulley, the second pulley and the second drive element being driven by the second motor of the second subset, wherein the second pulley is sized and arranged to engage the second endless loop element to thereby drive the second driven element.

9. The vehicle of claim 8, wherein the clutch mechanism further comprises: A third driven element rotatably coupled to and coaxial with the first driven element, the third driven element being sized and arranged to drivingly engage the first portion of the transfer mechanism and thereby transfer power from the first motor of the second subset when the first pivotable carrier is in the first angular orientation.

10. The vehicle of claim 9, wherein the clutch mechanism further comprises: A fourth driven element rotatably coupled to and coaxial with the second driven element, the fourth driven element being sized and arranged to drivingly engage the transfer mechanism second portion and thereby transfer power from the second motor of the second subset when the second pivotable carrier is in the first angular orientation.

11. The vehicle of claim 6, wherein the second drive system further comprises a plurality of omnidirectional wheels sized and arranged to frictionally engage corresponding portions of the underlying support surface to thereby support the vehicle.

12. The vehicle of claim 11, wherein the second drive system further comprises a plurality of drive axles, wherein at least one pair of the omnidirectional wheels is driven by at least one motor in the second subset of motors.

13. The carrier according to any one of claims 6 to 12, further comprising: A controller for directing operation of the plurality of motors, the controller comprising a processor and a memory containing instructions executable by the processor to operate the motors of the second subset to drive the first and second drive elements of the second drive system to thereby displace the vehicle along a horizontal path on the support surface.

14. The vehicle of claim 13, wherein the memory contains instructions executable by the processor to operate the second subset of motors to align corresponding portions of the first drive system with corresponding portions of the guidance system.

15. A vehicle according to claim 14, wherein the memory further contains instructions executable by the processor to initiate driving engagement of a corresponding portion of the first drive system with a corresponding alignment portion of the guidance system and thereby cause the vehicle to be raised or lowered relative to a reference plane.

16. The carrier of claim 15, wherein the clutch mechanism is configured to enable power to be transmitted to the transfer mechanism in response to the carrier being raised to a position above the reference plane, the memory further containing instructions executable by the processor for operating a motor of the second subset of one or more motors to cause the transfer mechanism to perform one of the following operations: transfer an item from the platform to a destination area adjacent to the carrier, or extract an item from the destination area to the platform.

17. The carrier of claim 15, wherein the clutch mechanism is sized and arranged to disable actuation of the transfer mechanism in response to the carrier being lowered to a position below the reference plane.

18. A vehicle capable of operating in an inventory management system having multiple destination areas and a guidance system, the vehicle comprising: a platform sized and arranged to receive items to be at least one of transferred to one of the destination areas or received from one of the destination areas; Multiple motors; a first motorized drive system configured to engage the guidance system to guide movement of the vehicle along a vertical segment; a second motorized drive system sized and arranged to maneuver the vehicle across a surface while the first motorized drive system is not engaged with the guide system; a transfer mechanism operative to transfer an item between the carrier and one of the plurality of destination areas; and a clutch mechanism operative to engage and disengage the transmission of power to and from the transfer mechanism, whereby each of the first motorized drive system and the second motorized drive system can be operated independently of the transfer mechanism; as well as wherein the first motorized drive system comprises first and second pairs of motor-driven rotating elements, the rotating elements of each pair being configured to interact with the guidance system to control the position of the vehicle along the guidance system; wherein the second motorized drive system comprises a first drive element driven by a first motor of a second subset of the plurality of motors to rotate about a first rotational axis, and a second drive element driven by a second motor of the second subset to rotate about a second rotational axis, wherein each of the first drive element and the second drive element is sized and arranged to engage a respective portion of an underlying support surface to effect movement of the vehicle thereon; The clutch mechanism comprises: a first pivotable carrier movable between a first angular orientation relative to the platform and a second angular orientation relative to the platform, wherein the first drive element is rotatably coupled to the first pivotable carrier for angular movement therewith; A second pivotable carrier is movable between the first angular orientation and the second angular orientation, wherein the second drive element is coupled to the second pivotable carrier for angular movement therewith.

19. The vehicle of claim 18, wherein each rotary drive element of the first and second pairs of motor-driven rotary elements is a gear having teeth sized and arranged to engage complementary teeth of the guide system as the vehicle changes elevation along the guide system.

20. The vehicle of claim 19, wherein the first motorized drive system further comprises a pair of synchronous drive axles, wherein driven gears are fixed to the axles such that the gears are synchronously driven to drive the vehicle along the guide system.

21. The carrier of claim 19, wherein the clutch mechanism is sized and arranged to disengage from the transfer mechanism as the carrier is lowered to a position beyond a reference plane, thereby disabling actuation of the transfer mechanism by a controller.

22. A carrier according to any one of claims 18-21, wherein the clutch mechanism is sized and arranged to engage the transfer mechanism as the carrier is raised to a position above a reference plane, thereby enabling actuation of the transfer mechanism by a controller.

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