Material handling apparatus having individual workstations and method of use

Abstract

A workstation for a material handling system is provided. The system can include a plurality of carriers for retrieving items from a plurality of storage locations located in one or more racks. The workstation is configured to receive the carriers such that the carriers drive into the workstation and upward along a track in the workstation. In one configuration, the track is configured to tilt the carriers at a predetermined angle relative to the horizon as the carriers drive upward. After the carriers are tilted to the predetermined angle, the carriers continue to drive upward while maintaining the predetermined angle.

Description

[0001] CLAIM OF PRIORITY

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 065,524, filed August 14, 2020, and U.S. Patent Application No. 17 / 403,814, filed August 16, 2021. The entire disclosure of each of the foregoing applications is hereby incorporated by reference herein. TECHNICAL FIELD

[0003] The present invention relates to a material handling system for storing or retrieving items. More specifically, the present invention relates to a material handling system incorporating a plurality of destination zones and a plurality of carriers for carrying items to and / or from the destination zones and carrying items to and / or from one or more workstations. BACKGROUND

[0004] Storing and retrieving items to fulfill customer orders can be laborious and time consuming, especially in systems that store thousands of items. Storing and retrieving items from thousands of storage zones requires a significant amount of labor to perform manually. In many fields, automated picking has been developed to reduce labor costs and improve customer service by reducing the time it takes to fulfill customer orders. However, known systems for automatically handling materials are very expensive or have limitations that impede their effectiveness. Accordingly, there is a need for a variety of material handling applications for automatically storing and / or retrieving items. SUMMARY

[0005] The present invention provides several inventive aspects relating to material handling and / or storing and retrieving processes.

[0006] According to one aspect, a picking station for a material handling system is provided having a plurality of independently operable carriers that deliver items. The picking station optionally includes a housing. The housing can have an opening configured to facilitate entry of the carriers into the picking station. Additionally, the picking station includes a track having a fixed track positioned within the housing such that a carrier driving through the opening in the housing is in operative engagement with the fixed track. The fixed track can be configured to guide the carrier vertically upward. Additionally, the track can include a lower section having a curved profile to tilt the carrier to a predetermined angle relative to the horizon. The track can also include an upper section having a generally straight profile to elevate the carrier a predetermined distance at the tilted angle.

[0007] According to another aspect, the picking station can include a monitor for identifying an item delivered to the picking station by a carrier that is to be removed from a container.

[0008] According to another aspect, the picking station can include a track including a plurality of vertical tracks.

[0009] According to another aspect, the picking station can include a track, the track including a plurality of teeth.

[0010] According to yet another aspect, the picking station can include a track having a first track element, the first track element having: a lower section having a first tooth pitch; and an upper section having a first tooth pitch. Optionally, the track can have a second track element, the second track element being opposite the first track element and having the first tooth pitch along substantially an entire length of the second track element.

[0011] According to another aspect, a method for charging a material handling vehicle can be provided, the vehicle being configured to drive in a horizontal direction along a first path and in a vertical direction along a second path. Each vehicle can include a power storage element. The method can include the step of driving a vehicle having an item to a picking station having a charging element, the charging element including a conductive element configured to provide a charging current to the vehicle to charge the power storage element of the vehicle. The method can also include the step of displacing an electrical contact of the vehicle into engagement with the charging element. Optionally, the vehicle can be elevated at the picking station while the electrical contact maintains electrical engagement with the charging element. Additionally, the charging element can be displaced as the vehicle is elevated upward at the picking station.

[0012] According to another aspect, a method for charging a material handling vehicle is provided, the method including the step of driving the vehicle upward at a picking station.

[0013] According to another aspect, a method for charging a material handling vehicle is provided, the method having the step of driving the vehicle upward by actuating a drive assembly of the vehicle.

[0014] According to yet another aspect, a method for charging a material handling vehicle is provided, the method including the step of displacing a charging element, and the displacing step including the step of vertically displacing the charging element to maintain operational engagement of the charging element with a charging contact of the vehicle as the vehicle is elevated upward.

[0015] According to another aspect, a method for charging a material handling vehicle includes the step of biasing a charging element in a vertical direction relative to a charging contact of the vehicle. Optionally, the method can additionally or alternatively include the step of biasing the charging element in a horizontal direction relative to the charging contact of the vehicle.

[0016] According to another aspect, a method for charging a material handling vehicle includes the step of driving a vehicle having a container to a picking station. Optionally, the method can include the step of driving the vehicle upward to an upper position such that the container is positioned at a raised position to submit the container to an operator at the picking station.

[0017] The present invention also provides a method for delivering an item from a storage system to a pick station. The method for delivering an item includes the step of driving a carrier having a container to the pick station. The carrier is driven upward at the pick station to an upper position to displace the container to a raised position to present the container to an operator. The container can be releasably held in the raised position. Optionally, the carrier can be driven downward away from the upper position while the container is held in the raised position. Driving the carrier downward while the container is held in the raised position can be used to decouple the carrier from the container. The method can also include the step of driving one or more subsequent carriers to the pick station to deliver items to be placed in the container while the container is held in the raised position.

[0018] According to another aspect, a method for delivering an item from a storage system to a pick station can include the step of driving an extraction carrier upward at the pick station to an upper position to operatively engage a container while the container is held in a raised position. Additionally, the method can include the step of releasing the container. Optionally, the method can include the step of driving the extraction carrier downward with the released container. Additionally, the method can include the optional step of driving the extraction carrier horizontally away from the pick station after the step of driving the carrier downward.

[0019] According to another aspect, the present invention can provide a work station for presenting an item carried by a carrier having a horizontal drive system for driving the carrier horizontally along a floor and a vertical drive system for driving the carrier vertically. The work station can include a track system including a rear track having a plurality of drive teeth, a front track having a plurality of drive teeth, and a cradle. The cradle optionally includes a first transfer mechanism that can cooperate with the rear track to drive the cradle upward and a second transfer mechanism that can cooperate with the front track to drive the cradle upward. The first and second transfer mechanisms can be configured to engage the vertical drive system of the carrier such that power from the vertical drive system is transferred through the first and second transfer mechanisms to drive the cradle upward along the track system to present the item on the carrier to an operator at the pick station.

[0020] According to another aspect, the present invention can provide a work station having a first transfer mechanism and a second transfer mechanism, and one of the transfer mechanisms optionally includes a first gear having a first pitch of teeth and a second gear element having a second pitch of teeth. Optionally, the work station can include a front track having a first segment having a pitch of teeth corresponding to the first pitch of teeth and a second segment having a pitch of teeth corresponding to the second pitch of teeth. Optionally, the first segment includes a curved profile configured to tilt the carrier to a predetermined angle, and the second segment is generally straight. BRIEF DESCRIPTION OF DRAWINGS

[0021] The foregoing summary of the preferred embodiments of the present application and the following detailed description thereof, will be best understood when read in conjunction with the following drawings, in which:

[0022] Figure 1 is a diagrammatic plan view of a materials handling system;

[0023] Figure 2 is Figure 1 is a fragmentary side view of a portion of the materials handling system shown in

[0024] Figure 3 is a perspective view of a carrier for use with the materials handling system shown in Figure 1

[0025] Figure 4 is an end view of the carrier shown in Figure 3

[0026] Figure 5 is a side elevational view of the carrier shown in Figure 3

[0027] Figure 6A is a perspective view of a workstation for use with the materials handling system shown in Figure 1

[0028] Figure 6B is a perspective view of an alternative workstation for use with the materials handling system shown in Figure 1

[0029] Figure 7 is a fragmentary rear perspective view of the workstation shown in Figure 6A

[0030] Figure 8 is a fragmentary front perspective view of the workstation shown in Figure 6A

[0031] Figure 9 is a partially cutaway perspective view of the workstation shown in Figure 6A

[0032] Figure 10 is a front end view of the track shown in Figure 9

[0033] Figure 11 is a rear perspective view of the track shown in Figure 9

[0034] Figure 12 is a fragmentary front perspective view of the workstation shown in Figure 9

[0035] ​​​​​​​​​​​Figure 13 for Figure 12 The image shows a magnified front perspective view of a partially cut section of the stent.

[0036] Figure 14 for Figure 13 The enlarged rear perspective view of a partially cut section of the stent shown in the image;

[0037] Figure 15 for Figure 12 An enlarged perspective view of the gears of the bracket shown in the image;

[0038] Figure 16 For use Figure 12 The image shows a partially cut-away, enlarged perspective view of the guide component of the support structure.

[0039] Figure 17 for Figure 6A The enlarged perspective view of the workstation shown in the image reveals details of the security door;

[0040] Figure 18 for Figures 3 to 5 The image shows an enlarged fragment view of the vertical drive gear of the vehicle; and

[0041] Figure 19 for Figure 6B A top-down view of the workstation. Detailed Implementation

[0042] Please refer to the various figures for a general overview and for more precise details. Figure 1 The equipment used for sorting or retrieving items is generally designated as 10. Equipment 10 includes one or more mechanisms for retrieving items from one of a plurality of locations, such as storage areas 25 located in shelf 20. The retrieval mechanism may include one or more vehicles that retrieve items from the storage location and deliver the items to workstation 200, where an operator can retrieve the items from the vehicles. The vehicles then return to the storage area in the shelf to store any remaining items not retrieved by the operator. The vehicles may then proceed to another storage area to retrieve the next item to be retrieved. In this way, the system may include mechanisms for continuously storing items in and retrieving them from various storage areas, enabling items to be delivered to an operator.

[0043] It should be understood that the individual items and subassemblies of the overall system can be used individually or in combination with material handling systems that have a different structure or operation than the systems shown in the figures and described below.

[0044] The material handling system 10 can include any of a variety of different systems for storing items. For example, the material handling system can include a system incorporating a plurality of autonomous vehicles, such as the system described in U.S. Patent Application No. 16 / 992,703, published as 2021 / 0047117 on February 18, 2021. The entire description of U.S. Application No. 16 / 992,703 is hereby incorporated by reference herein.

[0045] As shown in Figure 1 The material system can optionally incorporate one or more racks 20. Each rack can include a plurality of storage locations 25. Optionally, the storage locations can be arranged in one or more vertical columns 22. For example, Figure 1 A plurality of racks 20 are shown, and each rack can include a plurality of columns 22, each of which includes a plurality of storage locations. Items handled by the system can be stored directly in the storage locations. Alternatively, items can be stored in bins or totes 55, and the storage locations 25 can be configured to store the totes 55, as shown in Figure 2 Thus, it will be understood that, in the following description, when reference is made to a tote, the term tote is broad enough to include a container for containing one or more items, as well as the items themselves, which are not necessarily contained in a container, unless otherwise stated.

[0046] Referring again to Figure 1 , the system can include a plurality of racks 20, which optionally can be positioned to form rows or aisles 50. For example, a first rack 20a can be spaced apart from a second rack 20b such that an aisle 50a is formed between the two racks. In particular, the first rack 20a can be substantially parallel to the second rack to form an aisle having a substantially uniform width. Additionally, the system can include a plurality of racks forming a plurality of aisles 50. Although the aisles 50 are shown as being parallel in Figure 1 , it will be understood that the racks can be arranged in a variety of configurations if the system incorporates a plurality of racks 20, and the aisles need not be parallel if the system includes a plurality of aisles 50.

[0047] Optionally, the system includes automated elements for storing and retrieving totes from the storage locations. One such automated element is an autonomous vehicle. For example, as discussed further below, the automated elements can include a plurality of autonomous vehicles 100. Additionally, the automated vehicles 100 can be configured to transport totes 55 to a workstation 200. At the workstation 200, one or more items can be removed from a tote on one of the vehicles 100. In one embodiment, a human operator can remove the items from the vehicle. However, it will be understood that an automated mechanism can remove the items from the vehicle. Thus, it will be understood that the operator handling the items at the workstation 200 can be a human operator or an automated mechanism or a combination of the two.

[0048] The system 10 and / or various components of the system can be controlled by a central controller 90, such as a microcomputer. The central computer can receive signals from various elements, such as sensors, and control various aspects of the system based on the signals received from the various components. The central controller can also store data regarding the location of various items to be retrieved from the system. Additionally, the central controller can include data regarding the identity of items to be retrieved, such as a number of items to fulfill a customer order, and the quantity of such items. In this manner, the central controller can control and coordinate the operation of the various elements to schedule the retrieval and processing of multiple items from storage locations.

[0049] Rack system

[0050] As noted above, the system can include one or more racks 20 having a plurality of storage locations 25. Figure 1 and 2 Details of an exemplary storage rack 20 are shown in FIG. 1. However, it should be noted that the system can include any of a variety of elements for organizing a plurality of storage locations 25.

[0051] Referring to Figure 2 Each rack can include a plurality of support legs extending generally vertically and a plurality of shelves interconnecting the support legs extending generally horizontally. The shelves can be planar elements forming shelves such that the shelves form storage locations. However, in the embodiment shown in FIG. 1, the horizontal shelves are L-shaped shelves forming horizontal protrusions to support the edges of the totes 55. The horizontal shelves can be spaced apart from one another up the height of the vertical legs to form columns 22 of vertically spaced apart storage locations 25. Figure 2

[0052] As discussed above, the system can include a plurality of racks spaced apart to form one or more aisles 50. Optionally, a track 40 can be positioned along one or more of the racks, and the track can be configured to guide a carrier vertically such that the carrier can be transported up and down the columns 22 to the storage locations in the columns. Additionally, it can be desirable to position a first track along the racks on one side of the aisle, such as along the racks 20a, and a second track along the racks on the opposite side of the aisle, such as along the racks 20b. The carrier 100 can be configured such that the carrier travels in the aisle 50a such that it travels vertically along the track on the racks 20a while traveling vertically along the track on the racks 20b.

[0053] If the system utilizes one or more carriers and one or more racks, the racks can be configured to allow the carriers to travel under the racks 20 as well as to be able to travel across or along any aisle that can be incorporated into the system. For example, referring to Figure 1 ​, the vehicle can follow a path that moves along one or more segments that are parallel or transverse to the aisle. A first such path is designated as path 60a. Path 60a is within and parallel to aisle 50a. A second such path is designated as path 60b, which is parallel to the length of aisle 50a, but spaced apart from the aisle. In particular, path 60b is located below shelf 20b. Shelf 20b can be configured to provide clearance for the vehicle to move below the lowermost storage location 25, such that the vehicle can travel below shelf 20b along path 60b, which is parallel to the length of the aisle. A third path is designated as 60c, which is transverse to 60a and 60b. As shown in Figure 1 and 2 Path 60c is parallel to the depth of each column 22.

[0054] Figure 2 A plurality of vehicles are shown in different orientations relative to the shelves 20 and storage locations 25. For example, a first vehicle 100a is oriented to move horizontally along path 60c, traversing the length of the aisle 50. A second vehicle 100b is oriented to move horizontally below the shelves along path 60b, which is parallel to the length of the aisle 50. In addition, a third vehicle 100d is positioned within the aisle 50 to climb a vertical track along the shelves 20 on either side of the aisle. A fourth vehicle 100e is also positioned within the aisle and has climbed up the tracks 40a, 40b to a storage location 25 in an upper portion of the column 22. Finally, a fifth vehicle 100f is positioned below the shelves 20 and is oriented at an intermediate position between the orientation of vehicle 100a and the orientation of vehicle 100b. In particular, the shelves can be configured to facilitate rotation of the vehicle horizontally under the shelves. The fifth vehicle 100f shows the vehicle in the process of rotating from a first path to a second path under the shelves.

[0055] The vehicle

[0056] Figure 3 Details of one of the vehicles 100 shown in Figure 2 As noted above, the structure of the vehicle can vary if the system incorporates vehicles. Thus, it should be understood that each of the features of the vehicle discussed below is an optional feature that can vary or be excluded depending on the application.

[0057] The vehicle 100 can be an autonomous system that includes an onboard power supply for driving the vehicle. The vehicle can also include a communication system for receiving and transmitting control signals wirelessly between each vehicle and a control element, such as the central controller 90. In this way, the vehicle can receive control signals regarding the location from which to retrieve an item and the location to which the vehicle should deliver the item.

[0058] Figure 3The vehicle shown includes a horizontal drive assembly 120 for driving the vehicle 100 in a horizontal direction. The horizontal drive 120 can be configured to drive the vehicle along a track or along an open horizontal surface such as a floor. For example, one option for the horizontal drive includes multiple rotatable elements, such as wheels or rollers. One or more drive mechanisms can be provided for rotating the rotatable elements. Additionally, the rotatable elements can be rotated laterally to steer the vehicle.

[0059] Alternatively, such as Figures 3 to 5 As shown, the carrier may have a horizontal drive 120 formed by a plurality of rollers 122, 123, 124, which are rotatable about a first axis (e.g., about a wheel axle). Alternatively, the rollers 122, 123, 124 may be constrained to rotate about a single axis. For example, in Figures 3 to 5 In the illustrated embodiment, the horizontal drive 120 includes a pair of center rollers 124 and first and second sets of outer rollers 122, 123. The first set 122 may be positioned in front of the center rollers, while the second set of rollers 123 may be positioned behind the center rollers 124. The outer rollers 122, 123 may include rollers spaced apart along the length of the horizontal axle, such that... Figure 4 As shown, each set of outer rollers includes a first roller 122a on one side of the carrier and a second roller 122b on the opposite side of the carrier. Additionally, as... Figure 4 As shown, each set of outer rollers may include a pair of rollers 122b on each side of the carrier.

[0060] As described above, the vehicle 100 may have any of a variety of steering mechanisms for controlling the direction of travel of the vehicle. For example, an optional steering mechanism is a zero-turn mechanism, which can turn the vehicle without significant forward movement. Optionally, the zero-turn mechanism provides a component for rotating the vehicle about a vertical axis extending through the vehicle.

[0061] The zero-turn mechanism includes a link that allows a wheel or roller on one side of the vehicle to rotate at a different speed than a wheel or roller on the opposite side of the vehicle. Optionally, the link allows the wheel or roller on one side of the vehicle to rotate in a different direction than a wheel or roller on the opposite side of the vehicle. In this way, by changing the speed and / or direction of rotation of the wheel on one side of the vehicle relative to the speed and / or direction of rotation of the wheel on the opposite side of the vehicle, the zero-turn mechanism changes the direction of travel to steer the vehicle.

[0062] Optionally, the system may also include one or more guide elements 80 to guide or align the vehicle as it moves. For example, see Figure 4Guides 80 can include channels or grooves, and the carrier can include corresponding guide elements that cooperate with guides 80 to control movement of carrier 100. One example of a guide element is follower 126. A follower can be any element configured to engage or cooperate with guides 80. In the present example, carrier 100 includes a central follower 126 that includes a rotatable element, such as a bearing, that rotates about a vertical axis. Central follower 126 engages a channel in guide 80 to constrain horizontal movement of the carrier.

[0063] Optionally, the carrier can also include one or more lateral guide members 127. Lateral guide members 127 can cooperate with the outer surface of guides 80 to constrain movement of the carrier. For example, guides 80 can comprise a circular guide having a circumferential surface for guiding rotation of the carrier. The carrier can have a pair of lateral guide members 127 spaced apart from each other by a distance equal to the diameter of the circumferential surface of the guide. In this way, lateral guides 127 engage the circumferential surface of the guide to constrain the carrier to rotational motion.

[0064] In addition to horizontal drive mechanism 120, the carrier can also include a vertical drive mechanism 140 for driving carrier 100 vertically within rack 20. In particular, as described above, the system can include a guide mechanism, such as rails 40, disposed adjacent to rack 20. Vertical drive mechanism 140 can be configured to cooperate with vertical guide mechanism 40 to drive carrier 100 vertically.

[0065] Figures 3 to 4 An exemplary vertical drive 140 is shown that includes a plurality of rotatable gears 145, however, it should be understood that vertical drive 140 can include any of a number of drive mechanisms for driving a carrier vertically. Referring to Figure 4 , the vertical drive can include drive gears 145 that rotate about a horizontal axis that is transverse to the horizontal axis of rotation of horizontal drive mechanism 120. In particular, optionally, the carrier includes a pair of drive gears 145 that are spaced apart from each other such that the teeth of a first one of gears 145b protrude outward from a first side of the carrier and the teeth of a second one of gears 145d protrude outward from a second side of the carrier, as shown in Figure 4 . These first and second gears 145b and 145d can be driven synchronously. Additionally, as shown in Figure 3 , the carrier can include two pairs of vertical drive elements that are spaced apart from each other along the length of the carrier. In particular, optionally, the carrier includes a first pair of vertical drive elements 145a, 145c at a first end of the carrier and a second pair of vertical drive elements 145b, 145d at a second end of the carrier.

[0066] Referring to Figure 2 and 3The shelf 20 can be configured such that the rail 40a on one shelf and the rail 40b on the second shelf are spaced apart by a distance corresponding to the interval between the first set of vertical drive elements 145a and the second set of drive elements 145b. In this way, the first vertical drive element 145a can cooperate with the first rail 40a to drive the vehicle upward along the first rail 40a, while the second vertical drive element 145b can cooperate with the second rail 40b to drive the vehicle upward along the second rail 40b. Optionally, the two vertical drive elements 145a and 145b are driven synchronously, such that the vehicle maintains a horizontal orientation as it moves from horizontal movement to vertical movement.

[0067] The vertical actuator 140 can optionally be configured such that it maintains a substantially constant width as the vehicle transitions from horizontal to vertical movement. In this way, the vertical actuator 140 does not require an outward extension for the transition from horizontal to vertical drive. For example, see... Figures 3 to 4 The forward climbing gears 145b and 145d each have a horizontal axis of rotation, and the interval between the horizontal axes of rotation of the drive component 145b is fixed relative to the horizontal axis of rotation of the drive component 145d when the vehicle moves horizontally and when the vehicle climbs.

[0068] The vehicle may also include an optional transfer mechanism for transferring items between the vehicle and a destination, such as a storage location.

[0069] The transfer mechanism 150 can be used to transfer items between the platform surface of the vehicle and one of the plurality of destination areas 25. For example... Figure 3 As shown, the platform surface is optionally defined by the outer surfaces of multiple rollers.

[0070] The transfer mechanism 150 can be any of a variety of mechanisms for loading articles onto a carrier and unloading articles from a carrier into a storage area. Additionally, the transfer mechanism 150 can be specifically adapted for a particular application. In this example, the transfer mechanism 150 includes one or more movable elements configured to engage articles stored in a storage location and pull the articles onto the carrier. More specifically, in this example, the carrier includes one or more movable elements configured to move toward and releasably engage a transport box in the storage location. After the movable element engages the transport box, each movable element displaces away from the storage location, thereby pulling the transport box onto the carrier 100.

[0071] The movable element of the transfer mechanism can be any of a variety of items, such as bars, rods, or other elements configured to engage with items such as transport boxes. For example, see reference... Figures 3 to 4The transfer mechanism 150 can include one or more shiftable pins 152. Additionally, the transfer mechanism can include a drive element for shifting the pins 152. For example, optionally, the transfer mechanism 150 includes two drive elements in the form of an endless carrier, such as a drive belt or, as shown, a drive chain 154. Optionally, each pin 152 projects or extends inward toward the longitudinal centerline of the carrier. The transfer mechanism is preferably configured to cooperate with one of the totes to releasably engage the tote. For example, in the present example, the pins 152 are configured to mate with recesses on the tote such that the transfer mechanism can engage the tote. However, it should be appreciated that the transfer mechanism can include any of a variety of elements for engaging an item to be transferred onto or off of the carrier.

[0072] The carrier includes one or more drive elements for driving the transfer mechanism. Optionally, the carrier includes one or more motors that drive the transfer mechanism 150. For example, one or more motors of the carrier drive system can drive the chain 154 to selectively move the chain and pins 152 toward or away from the storage location.

[0073] As the carrier approaches the storage location to extract a tote T, the chain can drive the shiftable pins 152 toward the storage location such that the pins are positioned below the recesses or notches in the bottom of the tote. The carrier travels a small distance upward until the pins 152 are seated within the recesses or notches of the tote. The chain 154 is then reversed such that the pins 152 are moved away from the storage location. Because the pins engage the tote within the notches, as the pins are moved away from the storage location, they pull the tote onto the surface of the carrier. In this manner, the transfer mechanism 150 can be used to extract an item from the storage location. Similarly, to store an item in the storage location 25, the chain 154 of the transfer mechanism 150 drives the pins 152 toward the storage location until the item is in the storage location. The carrier then moves downward to disengage the pins from the tote, thereby releasing the tote.

[0074] In this example, as seen in FIG. 5, two or more totes, such as totes 55, can be coupled and uncoupled from one another using mating connectors. Optionally, the totes 55 can be coupled and uncoupled from one another via a series of lifting and separating movements implemented by movement of the carrier 100. Optionally, the transfer mechanism 150 can be actuated to pull a leading (“pilot”) tote onto the surface of the carrier so as to be fully supported by the carrier 100. If the totes are releasably connected, this pulling motion pushes a trailing tote (i.e., the tote immediately behind the pilot tote) into a position toward the aisle. Optionally, the vertical drive mechanism of the carrier 100 can then be used to vertically drive the carrier 100 to uncouple the pilot tote from the trailing tote. Once uncoupling is complete, the drive system can again be actuated to center the totes on the carrier 100. Figure 2 In this example, as seen in FIG. 5, two or more totes, such as totes 55, can be coupled and uncoupled from one another using mating connectors. Optionally, the totes 55 can be coupled and uncoupled from one another via a series of lifting and separating movements implemented by movement of the carrier 100. Optionally, the transfer mechanism 150 can be actuated to pull a leading (“pilot”) tote onto the surface of the carrier so as to be fully supported by the carrier 100. If the totes are releasably connected, this pulling motion pushes a trailing tote (i.e., the tote immediately behind the pilot tote) into a position toward the aisle. Optionally, the vertical drive mechanism of the carrier 100 can then be used to vertically drive the carrier 100 to uncouple the pilot tote from the trailing tote. Once uncoupling is complete, the drive system can again be actuated to center the totes on the carrier 100.

[0075] The vehicle 100 can include a separate drive element for driving the transfer mechanism 150. Alternatively, the transfer mechanism can be interconnected with one of the horizontal or drive elements of the vehicle. In particular, the transfer mechanism can be connected with one of the drive systems such that the drive system can be selectively operated between driving the vehicle and driving the transfer mechanism.

[0076] For example, the transfer mechanism can be optionally connected with one of the horizontal drive systems with an optional clutch mechanism such that in a first orientation the drive system drives the vehicle horizontally and in a second orientation the drive system drives the transfer mechanism. The optional clutch mechanism can selectively engage and disengage to initiate and terminate power transmission from the motor of the horizontal drive system to the transfer mechanism, respectively, whereby the second drive system can operate independently of the transfer mechanism. In this example, the clutch mechanism can be configured as two clutch subassemblies that are symmetrically arranged with respect to the longitudinal centerline of the vehicle 100.

[0077] Workstation

[0078] Referring now to Figures 6A to 17 , details of a workstation 200 that can be used in conjunction with or as part of the automated warehouse system 10 are shown. It should be understood that the workstation 200 is not limited to use in a particular automated warehouse system 10 such that features of the workstation 200 are independent of features of the automated warehouse system 10, such as the racks 20 and elements for extracting items from the racks, such as the vehicles 100.

[0079] The workstation 200 can have a single work area, referred to as a pick station 205, as shown in Figure 6B . Optionally, the workstation can have two work areas 205 positioned side-by-side, as shown in Figure 6A . In the following discussion, a single pick station 205 is described. It should be understood that if the workstation includes two pick stations, each of the pick stations is generally similarly configured.

[0080] The pick station 205 can optionally be configured to work with independent vehicles, such as the vehicles 100 described above. Thus, the pick station 205 can be configured to cooperate with the vehicles to raise the vehicles upwardly so that an operator can easily extract items from the vehicles when the operator is positioned at the pick station. For example, the pick station 205 can incorporate elements for lifting each vehicle as the vehicle arrives at the pick station 205. The lifting elements can be driven by the pick station 205. For example, each pick station can include an elevator for lifting the vehicles, and the pick station can include a motor or other mechanism for driving the elevator. Alternatively, as described below, the drive elements for lifting the vehicles 100 can be provided by the vehicles.

[0081] The pick station 205 can include a housing 210 that provides a shell for the pick station. The housing can include side walls 212 and an upper surface 215. The housing can optionally include a front leg 222 that supports the front of the pick station 205 and a rear leg 224 that supports the rear of the pick station. The front leg 222 and the rear leg 224 can include adjustable feet that extend or retract to adjust the height of each leg. The side walls 212 can have openings 214 configured to allow a carrier to drive through the side walls into the pick station 205.

[0082] Referring to Figure 6A , 6B and 19, the upper surface 215 can have a pick opening 216 so that an operator can pass through the pick opening to extract an item carried on a carrier 100. The pick opening 216 can have a length and width that corresponds to the length and width of a tote 55 that can be used to store items in a storage rack 20. Optionally, each tote can have an upper rim that defines the upper surface of each tote.

[0083] The internal length and width of the interior of the tote adjacent the rim can be substantially similar to the length and width of the pick opening 216. If the tote has this optional configuration, the tote 55 can span the entire length and width of the pick opening so that when the tote is positioned within the pick opening, the tote obstructs passage between the rim of the tote and the edges of the pick opening. In particular, the tote is sized and configured to cooperate with the pick opening to prevent a hand of an operator from passing between the tote and the pick opening. In other words, the tote can operate as a stop that obstructs an operator from passing through the pick opening 216 to extend an accessory into the interior of the pick station 205.

[0084] Optionally, the workstation can include a projector 220 for projecting light and optionally images onto the workstation. The projector 220 can be mounted above the upper surface 215 for projecting light down onto the upper surface and onto the area enclosed by the pick opening 216. When a tote is raised into an upper position as shown in Figure 19 , the projector can be controlled by the central controller to selectively project light and images onto variable locations on the upper surface 216 and / or onto the area of the tote 55.

[0085] As shown in Figure 19 , the upper surface 215 of the pick station 205 can frame the pick opening 216, thereby framing the tote 55. The upper surface 215 optionally provides a projection surface onto which a projector can project images that provide information to an operator. For example, the projector 220 can project one or more images onto the upper surface and also project light onto a portion of the tote. In Figure 19In this example, the first image 405 indicates the number of items to be removed from the tote 55. Optionally, as shown in Figure 19 In this example, the first image 405 indicates the number of items to be removed from the tote 55. Optionally, as shown in

[0086] The central controller monitors the carriers and the totes carried by the carriers. The central controller additionally monitors the number of items to be picked from the totes at the workstations. Accordingly, the central controller controls the projectors such that the projectors project one or more identifying signs for the operator when the tote is raised to the upper position. Preferably, the central controller controls the projectors to selectively project at least two signs, at least one of the at least two signs including a graphical image projected onto a surface adjacent to the tote. The signs are selectively projected in response to tracking of the items in the tote and data regarding the number of items required.

[0087] The door

[0088] As discussed above, the picking station can optionally be configured to cooperate with the tote such that the tote blocks the pick opening 216 when the tote is raised to the pick opening. Additionally, the picking station can include an optional removable cover plate that selectively covers the pick opening 216. For example, the picking station 205 can include a movable closure mechanism or covering that overlies the pick opening to obstruct the passage of items through the pick opening. In a first position, the closure covers the pick opening to operate as a barrier to prevent items from passing through the pick opening; in a second position, the closure uncovers the pick opening to allow items to pass through the pick opening. In one embodiment, the closure can be a movable door 230. In a first position, the door is closed to cover the pick opening. In a second position, the door is moved away from the pick opening to uncover the pick opening, as shown in Figure 6A

[0089] The optional door 230 can be any of a variety of elements for covering the pick opening. Figure 6A 、 8 One example is shown in FIGS. 16-17, which includes a plurality of door segments 232 connected by a series of pivotable connectors, such as hinges 234. The picking station can include a mechanism for automatically driving the door 230 between the open and closed positions.

[0090] As discussed above, the picking station can optionally be configured to cooperate with the tote such that the tote blocks the pick opening 216 when the tote is raised to the pick opening. Additionally, the picking station can include an optional removable cover plate that selectively covers the pick opening 216. For example, the picking station 205 can include a movable closure mechanism or covering that overlies the pick opening to obstruct the passage of items through the pick opening. In a first position, the closure covers the pick opening to operate as a barrier to prevent items from passing through the pick opening; in a second position, the closure uncovers the pick opening to allow items to pass through the pick opening. In one embodiment, the closure can be a movable door 230. In a first position, the door is closed to cover the pick opening. In a second position, the door is moved away from the pick opening to uncover the pick opening, as shown in Figure 17 ​As shown in FIG. 2, door closer 240, in the form of a belt 244 driven by a drive shaft 246, can drive the door between open and closed positions. The hinges 234 of the door segments can be attached to a plurality of hinge bodies 242 that slide within a groove. Connectors 242, such as brackets or blocks, can interconnect one or more of the hinge bodies 234 with the drive belt 244, such that driving the hinge bodies in a first direction causes the door to extend over the pick opening 216 and driving the hinge bodies in a second direction causes the door to retract from the pick opening.

[0091] track

[0092] The pick station 205 can include a mechanism for elevating the carrier 100 at the pick station to present the tote 55 to an operator working at the pick station. For example, the pick station can include an elevator that lifts the carrier 100 after the carrier enters the workstation 200. This elevator can be powered by a power source at the workstation. Alternatively, the carrier 100 can provide the power source for lifting or elevating the carrier at the workstation 200. For example, the workstation 200 can include a track or guide element 250 and the carrier 100 can include a climb element for climbing the track. For example, the vertical drive 140 of the carrier 100 can cooperate with the track 250 such that the carrier can move vertically up and down within the workstation 200.

[0093] In this example, the workstation 200 can be configured such that the tote is tilted toward the operator as it is lifted toward the operator. For example, the workstation 200 can include an optional curved track 250 that curves toward the front of the workstation such that the tote 55 is tilted toward the operator as the carrier is driven upward. Referring now to FIG. 3, an example of a curved track 250 is shown. The curved track 250 can include a pair of front tracks 260 and a pair of rear tracks 270 that are spaced apart from each other. The front and rear tracks 260, 270 form a vertical column of four corners that curve upward from back to front. The front and rear tracks can be rigidly connected. For example, a pair of side bars 226 can connect the front tracks 260 to the rear tracks 270. Figure 10 and 11 Details of the optional curved track 250 will be described in greater detail. It should be understood that the features of the curved track are optional such that one or more of the features can be incorporated into the track while others can be eliminated depending on the application.

[0094] Although the pick station is shown and described as having a housing that encloses a frame including the curved track 250, it should be understood that in some applications the curved track can provide the structural support for the pick station. And optionally, the housing can be modified or eliminated.

[0095] Figures 10 to 11 An example embodiment of the optional track 250 is shown in FIG. 3. The track 250 includes a pair of front tracks 260 spaced apart from each other and a pair of rear tracks 270 spaced apart from each other. The front and rear tracks 260, 270 form a vertical column of four corners that curve upward from back to front. The front and rear tracks can be rigidly connected. For example, a pair of side bars 226 can connect the front tracks 260 to the rear tracks 270.

[0096] As Figure 10As shown, each side bar 228 extends at an angle relative to the horizon, angled upwards from front to back to rigidly connect the top of one of the front rails 260 to the top of the rear rail 270 on the same side of the picking station. Additionally, a pair of crossbars 228 extend across the width of the picking station to connect the front rails 260 and the rear rails. Specifically, a first crossbar 228 extends between the two front rails 260 to rigidly connect the front rails, and a second crossbar 228 extends between the two rear rails 270 to rigidly connect the rear rails. In this way, the front and rear rails can be connected to form independent tracks.

[0097] If the track is curved, such as optionally in Figures 9 to 12 As shown, the length of the front track 220 is shorter than the length of the rear track 270. Therefore, the rear end of the vehicle 100, which engages with the rear track 270, moves faster than the front end of the vehicle, which engages with the front track 260. To accommodate this speed difference, the interface between the vehicle 100 and the tracks can be modified to account for the relative speed difference. For example, the front track 260 and the rear track 270 may each have multiple teeth operating similarly to teeth on a rack. The tooth spacing of the front track may differ from the tooth spacing of the rear track. For example, the front track may have a smaller tooth spacing than the rear track (e.g., an M6 module). In this way, if the vertical drive has synchronously driven vertical drive wheels, the rear wheel travels a greater distance per revolution of the vertical drive wheel than the front wheel.

[0098] While track 250 may optionally include a front track with a different spacing from the rear track, it should be understood that alternative configurations may be incorporated to tilt the vehicle as it rises at the picking station. For example, the vertical drive of the vehicle may be configured such that the vertical drive mechanism at the rear edge adjacent to the picking station drives faster than the vertical drive mechanism at the front edge adjacent to the picking station. In either configuration, the edge of the vehicle at the rear edge adjacent to the picking station moves upward faster than the edge of the vehicle at the front edge adjacent to the picking station.

[0099] As discussed above, the track and the vehicle can be configured to cooperate such that the rearward edge of the vehicle 100 adjacent to the rear track 270 moves upward relative to the front edge of the vehicle, causing the vehicle to tilt toward the operator. In this way, the transport container is delivered to the operator for improved retrieval of the items in the transport container.

[0100] See Figure 10The track 250 can optionally be configured such that the track has a first section that tilts the vehicle as it moves upward and a second section that drives the vehicle upward at a constant angle relative to the horizon. In this way, the vehicle is tilted as it moves upward to a predefined point at which the vehicle forms a predefined angle relative to the horizon. After this predefined point, the vehicle moves upward while maintaining the vehicle at the predefined angle relative to the horizon.

[0101] Figure 10 A track 250 is shown having a lower section configured to tilt the vehicle and an upper section configured to raise the vehicle at a constant angle relative to the horizon. For example, the front track 260 can have a lower curved section 262 that follows a radius of curvature. Similarly, the rear track 272 can have a lower curved section 272 that follows a radius of curvature. The radius of curvature of the rear lower track 272 is greater than the radius of curvature of the front lower track 262. In addition, the front track 260 includes an upper section 266 that extends substantially linearly from the end of the lower curved section 262. Similarly, the rear track 270 includes an upper section 274 that extends substantially linearly from the end of the lower curved section 272. In addition, the upper section 266 of the front track can extend substantially parallel to the upper section 274 of the rear track.

[0102] As described above, the front track 260 and the rear track 270 can have curved lower sections and linear upper sections. In addition, the pitch of the two curved lower sections 262, 273 is different to allow for relative shifting of the front of the vehicle relative to the rear of the vehicle. However, the pitch of the linear upper sections 266, 274 can be constant such that the front and rear of the vehicle move at a substantially constant rate such that the angle of the vehicle relative to the horizon is substantially constant.

[0103] Because the pitch of the lower sections is different but the pitch of the upper sections is the same, one of the tracks has a different pitch on the curved section than on the linear section. In this example, the front track has a curved lower section with a first pitch, e.g., M4, and a linear upper section 268 with a second pitch, e.g., M6. Optionally, the upper section and the lower section are offset. In particular, a lower groove 264 having a width can extend vertically alongside the lower curved section 262 such that the lower groove 264 is substantially coextensive with the lower curved section. The upper linear section 266 can have a width that is substantially the same as the width of the lower groove, and the upper linear section can extend from the end of the lower groove 264. In addition, an upper groove 268 having a width similar to the width of the lower curved track 262 can extend vertically alongside the upper linear track 266.

[0104] Support

[0105] As described above, the workstation 200 can include a track 250 that guides the carrier so that the carrier can climb vertically to present the tote to the operator. The track 250 and carrier 100 can be configured so that the carrier can directly engage the track to climb the track. Alternatively, as described below, the workstation 200 can include a carriage 300 on which the carrier rides and that climbs the track to elevate the carrier toward the operator.

[0106] A variety of carriages can be used to elevate the carrier, including a single piece carriage that extends the width of the side of the workstation 200. Alternatively, as described below, the carriage can comprise multiple independent segments. An elevator provides an interface between the power source and the carrier to raise the carrier. For example, the carriage can be connected with a power supply, such as a power source that powers a motor to raise the carrier. Alternatively, as described below, the carriage can provide a mechanism to elevate the carrier using power from the carrier. In the following example, the carriage provides a drive bearing to transfer driving force from the carrier to a climbing mechanism that climbs the track 250 and tilts the carrier.

[0107] Figures 7 to 10 The carriage 300 shown in Figures 12-16 includes a front carriage assembly 310 and a rear carriage assembly 320. The front carriage assembly 310 and the rear carriage assembly 320 are generally similar, however, one of the two assemblies can include a charging assembly. As discussed below, the rear carriage assembly 320 is shown incorporating a charging assembly. In the following description, the rear carriage 320 will be described in detail. It should be understood that the front carriage 310 includes features similar to those described below for the rear carriage except for details related to the charging assembly.

[0108] Referring now to Figure 7 , 9 and 13, the rear carriage 320 includes an elongated, generally vertical sidewall having a length that extends between the two rear tracks 270. The sidewall 322 can include a pair of apertures 324 spaced along the length of the wall. The first aperture can be adjacent to the first rear track 270 and the second aperture can be adjacent to the second rear track.

[0109] Optionally, the rear carriage assembly 320 can include a plurality of gears that cooperate with the vertical drive 140 of the carrier to elevate the carrier at the picking station 200. For example, the rear carriage 320 can include a first drive gear 330 adjacent to the first rear track 270 and a second drive gear 330 adjacent to the second rear track. As shown in Figures 12 to 13 the drive gears 330 can extend through the windows 324 in the sidewall 322.

[0110] The drive gear 330 is rotatably mounted on a shaft 339. The shaft 339 can be mounted on a yoke 338 that spans the window 324 in the sidewall, such that a first end of the yoke is on one side of the window and a second end of the yoke is on an opposite side of the window.

[0111] Referring to Figure 12 , the drive gear 330 operates as a loose gear between the vertical drive 140 of the carrier and the track 250. Specifically, the drive gear engages the drive gear 145 of the vertical drive 140 as well as the teeth of the backward track segment 270. In this way, the vertical drive gear 145 drives the drive gear 330, which drives the carriage vertically along the track 270. Driving the vertical drive gear 145 in a first direction drives the carriage upward along the track 270; driving the vertical drive gear 145 in a second direction drives the carriage downward along the track 270.

[0112] Optionally, the carrier 200 can include structure for engaging the carriage 300 such that the carriage supports the weight of the carrier. For example, the carrier can include a support element that protrudes generally horizontally. In Figure 12 , the support element is shown as a pin or post 165, and the carrier can include multiple such support elements. Optionally, the carrier can include a support element adjacent to four corners of the carrier, such that the front and back sides and both sides of the carrier are supported.

[0113] The carriage can include structure to cooperate with the vertical support elements 165 on the carrier 200. For example, as shown in Figure 13 , the carriage subassembly 320 can include one or more blocks, stops, cradles, or other elements 370 with surfaces to support the vertical support elements 165 of the carrier. The support cradle 370 can have a horizontal surface to support the support pin 165. In the shown embodiment, the support cradle 370 includes a v-shaped groove that is configured such that the support pin 165 nests within the v-shaped groove.

[0114] The support elements 165 on the carrier can be positioned such that the support elements are spaced above the support cradles 370 on the carriage 300, as shown in Figure 12 . In this way, a gap is formed between the top of the support cradle and the bottom of the support element 165. The gap allows the support pin 165 to pass over the support cradle 370 as the carrier is driven into or through the picking station 200.

[0115] The support elements 165 on the carriers cooperate with the support brackets 370 on the carriage to raise and lower the carriers at the pick station. For example, the vertical drive gears 145 of the carriers can drive the drive gears 330 of the carriage 300 to drive the carriage upward. As the carriage is driven upward, the support brackets 370 engage the support pins 165 such that the support pins rest within the v-shaped grooves in the support brackets. As the carriage is driven further upward, the support brackets 370 support the weight of the carriers via the support pins such that the carriage lifts the carriers upward. Similarly, as the carriage is lowered, the support brackets 370 support the support pins such that the carriers lower with the carriage.

[0116] As described above, the front carriage assembly 310 can be substantially similar to the rear carriage assembly 320. Additionally, as described above, the front track 260 can be configured differently than the rear track 270, for example in applications where the track 250 is curved to tilt the tote 50 toward the operator at the pick station 200. Thus, it can be desirable to configure the drive gears 330 for the front carriage 310 differently than the drive gears for the rear carriage. For example, the drive gears 330 for the rear carriage 320 can be a pinion gear with a single set of gear teeth to cooperate with the rear track 270, and the front carriage can incorporate a compound gear 330' with two sets of gear teeth, as shown in Figure 15 However, it should be understood that if the front carriage and the rear carriage have different drive gears, the track can be configured such that the rear carriage has multiple gear elements, for example the compound gear shown in Figure 15

[0117] Referring to Figure 15 , an optional compound drive gear incorporated into the front carriage 310 is shown. The drive gear 330' can include two separate coaxial gears with different tooth spacing that rotate at the same speed. However, in this example, the drive gear 330' comprises a unitary piece with two gear elements fixedly connected with the central hub 332. For example, the drive gear can have a first gear 334 integrally formed with the central hub 332 that is configured to cooperate with a first portion of the front track 260, and a second gear 336 integrally formed with the central hub 332 that is configured to cooperate with a second portion of the front track. For example, optionally, the first gear 334 is configured with a gear spacing designed to mesh with the upper portion 266 of the front track 260, and the second gear 336 is configured with a gear spacing designed to mesh with the lower portion 262 of the front track. Additionally, the drive gear 330' can be configured such that the first gear 334 has gear teeth with a greater tooth length than the gear teeth of the second gear 336, such that the gear teeth of the second gear protrude further outward from the central hub 332 than the gear teeth of the first gear.

[0118] ​The drive gear 330' can optionally be mounted to the front carriage 310 such that the first gear 334 is aligned with and / or overlies the lower recess 264 of the front track. Additionally, the first gear can be configured such that the first gear does not mesh or contact with the lower rack section 262 of the front track 260. In this manner, the first gear 334 is spaced from the lower rack section such that the first gear 334 does not engage with the lower rack section.

[0119] Referring to Figure 11 and 15 , the drive gear 330' is configured and positioned such that the smaller diameter gear 336 engages with the lower rack section 262 to drive the carrier 100 upward. At the same time, the lower recess 264 provides clearance for the larger diameter first gear 334. As the carrier climbs upward, the smaller gear 336 reaches the end of the lower track section 262. At the end of the lower track section, continued upward displacement of the carrier causes the drive gear to transition from the lower track section 262 to the upper track section 266. The transition occurs when the larger gear 334 engages the upper track section 264 and the upper recess 268 provides clearance for the smaller gear 336. Continued drive of the drive gear 330' drives the carriage upward along the upper track section as the first gear 334 engages the upper track section 266.

[0120] Similarly, the upper and lower track sections cooperate with the drive gear 330' to lower the carriage 300. In particular, the first gear 334 engages the upper track section 266 until the first gear reaches the end of the upper track. Continued drive of the drive gear after the first gear reaches the end of the upper track causes the drive gear to transition from the upper track to the lower track section such that the second gear 336 engages the lower track section and the lower recess 264 provides clearance for the first gear 334.

[0121] As previously discussed, the vertical drive 140 of the carrier 100 can include a plurality of drive gears having outwardly projecting teeth. Optionally, the spacing of the drive gears relative to one another can be fixed during operation of the carrier as the carrier travels along the ground and as the carrier climbs in the rack. Similarly, the climb gears can have a fixed spacing relationship as the carrier is elevated vertically at the work station 200.

[0122] Thus, as shown in Figure 10 and 12 , the rotational axis of the vertical drive gears 145 is parallel to the rotational axis of the drive gear 330 of the carriage when the carrier is in the work station 200. Thus, when incorporating this optional combination of vertical drive elements and drive gears, it is desirable to configure the teeth of the vertical drive gears 145 and the drive gear to facilitate the teeth of the vertical gears passing through the teeth of the drive gear as the carrier enters the work station.

[0123] As Figure 12 shown in

[0124] Referring again to Figure 12 , optionally, when the carrier is driven into the workstation (i.e., when the vertical drive gear is translated such that the rotational axis of the vertical drive gear is parallel to the rotational axis of the drive gear), the vertical drive gear 145 and the drive gear 330 can be configured and oriented such that the vertical drive gear passes through the drive gear with increased clearance. Thus, when the carrier is at its lowest point, the operational clearance between the vertical drive gear and the drive gear is maximized, as Figure 12 shown in

[0125] As the carrier is driven upward along the track, the operational clearance between the vertical drive gear and the drive gear can decrease such that the gear centers move toward the standard center distance. Specifically, the track 250 can be configured such that the distance between the front track and the back track is not constant along the height of the track. For example, the reference lines of the teeth of the front track and the back track can be configured such that the distance between the two reference lines gradually decreases along the height of the track. The spacing between the reference lines of the track can continue to decrease along the entire height of the track. In the present example, however, the spacing of the track reference lines decreases to a predetermined distance and then remains constant for the upper portion of the track. By decreasing the distance between the reference lines of the front and back tracks, the track guides the drive gear toward the vertical drive gear, thereby increasing the contact ratio between the vertical drive gear and the drive gear.

[0126] As described above, when the carrier enters the workstation, the vertical drive gear 145 and the drive gear 330 are spaced apart at a maximum distance to maximize the clearance to facilitate translation of the vertical drive gear relative to the drive gear. Optionally, the track 250 can be configured such that the track guides the drive gear toward the vertical drive gear as the carrier is driven upward along the track. In this way, the system is configured such that the operational clearance decreases as the carrier is driven upward along the track.

[0127] The carriage 300 can be a unitary item that interconnects both the front carriage assembly 310 and the rear carriage assembly 320. Alternatively, as shown in Figure 10 The carriage can include separate front and rear carriages 310, 320 that operate independently. If the carriage 300 includes separate front and rear carriages, it can be necessary to utilize a retainer to retain the drive gear 330 in operative engagement with the track 250.

[0128] Referring to Figure 11 and 16 , details of an optional retainer are shown. The retainer can include a component mounted on the workstation 200 that cooperates with a component mounted on each carriage 310, 320 to retain the drive gear 330 in operative engagement with the track. In this example, a guide rail 280 is mounted on the track 250. In particular, the guide rail 280 includes an elongated channel or groove positioned adjacent to each segment of the track, as shown in Figure 11 Additionally, a follower assembly 380 can be connected with the carriage. It should be understood that the follower assembly can be connected to each end of both the front carriage 310 and the rear carriage 320. As shown in Figure 16 The follower assembly 380 includes a bracket 382 connected with the rear carriage 320 and projecting transverse to the side wall 322 on the rear carriage. One or more internal follower elements 384 are mounted to a distal end of the bracket away from the side wall of the rear carriage. The internal follower elements 384 are configured to cooperate with the groove of the guide rail 280.

[0129] In this example, the internal follower elements 384 are roller bearings having a diameter corresponding to the width of the groove in the guide rail 280. The follower assembly can also include external follower elements 386 configured to cooperate with a second surface of the guide rail 280. For example, the follower 380 can include a third bearing 386 spaced apart from the internal bearing 384. The gap between the internal bearing 384 and the external bearing 386 can be similar to the wall thickness of the guide rail 280, such that the internal bearing 384 follows the inner wall of the groove and the external bearing 386 follows the outer wall of the guide.

[0130] Charging assembly

[0131] The picking station 200 can optionally include a charging mechanism for charging the vehicles 100. The charging mechanism can be connected with the power source 95 to provide a charging current to recharge the power supply of the vehicles. For example, optionally, each vehicle includes an on-board rechargeable power source. The rechargeable power source can be a rechargeable battery. However, in this example, the vehicles include a power source that includes a plurality of ultracapacitors that can be quickly recharged. For example, the power source can include a plurality of super or ultracapacitors sufficient to power the vehicle when moving horizontally or vertically with a payload of 30 to 40 kilograms.

[0132] The charging mechanism can be any of a variety of elements used to provide charging current to the vehicle. For example, in this instance, the charging mechanism can be a charging rail 340 that cooperates with electrical contacts 160 on the vehicle 100.

[0133] like Figure 13 As shown, the charging rail 340 may include one or more elongated conductive elements. The rail may form one or more channels or grooves configured to cooperate with electrical contacts of the carrier. For example, such as Figure 12 As shown, the carrier may include one or more charging contacts, such as brush 160. Brush 160 may project outwards from the carrier. Brush 160 is oriented and configured to mate or cooperate with charging rail 340. For example, as... Figure 13 As shown, the charging rail can be horizontally oriented and can protrude horizontally outward from the rear of the vehicle, so that when the vehicle is in the bracket 300, the brush protrudes to make electrical contact with the charging rail.

[0134] The charging rail 340 can be rigidly mounted to the track 250 or the housing 210 such that the charging rail does not move relative to the track 250 or the housing 210. Alternatively, the charging rail can be displaced relative to the track or the housing 210. Optionally, the charging rail can be connected to a support such that the charging rail moves with the support. For example, when the support 300 moves vertically along the track 250, the charging rail can move vertically upward and downward. In this way, when the support and the charging rail 340 are vertically displaced, the charging contact 165 of the carrier 100 can remain electrically connected to the support 300. In other words, the charging rail 340 can be configured to continue supplying charging current to the carrier 100 when the carrier and the charging rail are vertically displaced at the picking station.

[0135] Optionally, the charging rail 340 may be horizontally displaced relative to the carrier 100 so that the charging contacts 165 of the carrier are horizontally aligned with the charging rail.

[0136] In one embodiment, the charging rail 340 may be displaceably connected to the bracket 300, such that the charging rail 340 may be horizontally displaced toward and away from the vehicle. Optionally, the charging contacts of the vehicle may be horizontally and / or vertically displaced relative to the charging rail 340.

[0137] Various connections can be incorporated to provide a movable connection between the bracket 300 and the charging rail 340. For example, the connection can be an offset connection, such that the charging rail is offset horizontally toward the vehicle away from the side wall 322 of the bracket 300.

[0138] Figure 14An optional embodiment incorporating a biased connection is shown in FIG. 3. In this embodiment, the cradle includes one or more lateral adjustment mechanisms 350 that bias the charging rails toward the vehicle 100.

[0139] The lateral adjustment mechanisms 350 can include a plurality of horizontal bars 352 that are horizontally displaceable relative to a mounting bracket 356. Additionally, the lateral adjustment mechanisms 350 can include one or more rigid bars that rigidly connect the bracket 356 with the cradle. One or more biasing elements 354 bias the displaceable bars 352 toward the vehicle. The biasing elements 354 can be any of a variety of elements, such as an elastomeric member or a spring. In the present example, the biasing elements are helical compression springs that surround the displaceable bars 352.

[0140] Optionally, the charging rails 340 can be vertically displaceable relative to the vehicle 100 to vertically align the charging contacts 165 of the vehicle with the charging rails. For example, the charging rails 340 can be displaceably connected with the cradle 300 such that the charging rails 340 are vertically displaceable relative to the vehicle.

[0141] A variety of connections can be incorporated to provide a vertically displaceable connection between the cradle 300 and the charging rails 340. In one embodiment, the connection can be a biased connection such that the charging rails are vertically biased relative to the side walls 322 of the cradle 300.

[0142] Figure 14 An optional embodiment incorporating a biased connection is shown in FIG. 3. In this embodiment, the cradle includes one or more lateral adjustment mechanisms 350 that bias the charging rails toward the vehicle 100.

[0143] Optionally, the vertical adjustment mechanisms 360 can include one or more stops that limit the travel of the vertical bars relative to the support blocks 364. Although a variety of items can be used as such stops, Figure 14 One non-limiting example is shown in which the stop is a snap ring positioned along the length of the vertical bar.

[0144] One or more biasing elements 363 vertically bias the vertical bars 362. The biasing elements 363 can be any of a variety of elements, such as an elastomeric member or a spring. In the present example, the biasing elements are helical compression springs that surround the vertical bars 362.

[0145] The optional displaceable connection of the charging rail 340 allows the charging rail to be displaced relative to the vehicle as it enters the cradle. In one example, the charging rail can be displaced in a first direction to allow the charging rail to align with the electrical contacts of the vehicle. Similarly, and optionally, the charging rail can be displaced in a second direction transverse to the first direction to allow the charging rail to align with the electrical contacts of the vehicle.

[0146] Additionally, the charging rail 340 can include one or more guides or deflectors, such as tapered fingers 345, which can engage with the brushes 165 of the vehicle to align the brushes into the channels of the charging rail. In particular, the guides 345 can include one or more tapered surfaces to vertically deflect the charging rail relative to the brushes as the brushes engage the guides.

[0147] In the foregoing examples, the charging rail 340 can be displaceably connected to the cradle 300 vertically and / or horizontally, such that the cradle can be displaced relative to the electrical contacts 165 of the vehicle. Alternatively, the charging rail 340 can be substantially rigidly connected relative to the cradle, and the electrical contacts can be displaceable relative to the vehicle vertically and / or horizontally to align the electrical contacts with the charging rail as the vehicle enters the cradle.

[0148] Tote Retainer

[0149] As described above, the vehicle 100 delivers an item, such as a tote 55, to the workstation 200, and the vehicle is vertically raised to elevate the tote into the pick opening 216 so that an operator can remove the item from the tote. The vehicle then lowers down toward the floor with the tote. However, there can be applications where it is desirable to hold the tote in an elevated position while the vehicle lowers down. In this way, the tote can be held in an elevated position at the pick station 205 while the vehicle 100 drives to a different location to perform a separate task in order to retrieve another tote 55. Accordingly, as shown in FIG. 21, the pick station 205 can include an optional retainer mechanism 290 for holding the tote in an elevated position. Figure 17

[0150] The retainer mechanism 290 includes a mechanical element that can be displaced between a retracted position and an extended position. In the extended position, the retainer projects inwardly toward the tote. As shown in FIG. 22, the tote can have an upper lip or flange. In the extended position, the retainer mechanism 290 projects toward the tote so that the retainer mechanism extends under the lip of the tote. In this way, if the vehicle moves down, the retainer operates as a stop that impedes the downward movement of the tote. Figure 9

[0151] The retainer mechanism 290 can include any of a variety of elements for engaging the tote. Figure 17 ​​An example mechanism is shown. In particular, the retainer mechanism can include a pivotable finger or arm 292, referred to as a paddle. The paddle 292 is a longitudinally elongated element that pivots about a pivot axis located proximate a first end of the paddle. A second end of the paddle 292 pivots between a retracted position and an extended position. In the retracted position, the paddle is retracted away from the pick window 216 so that the tote can be easily moved up and down as the carrier moves up and down on the track 250. In the extended position, the paddle extends into the pick window 216 so that the paddle engages the tote to prevent the tote from moving downward.

[0152] The retainer mechanism 290 includes a drive element for driving the retainer mechanism between the retracted position and the extended position. The drive element can be a separate drive mechanism, such as a solenoid, motor, or other actuator. Optionally, as shown in FIG. 2, the drive mechanism for the door 230 covering the pick window 216 also drives the retainer mechanism. In particular, the connector 294 connected with the door driver 240 is also connected with a linkage 296 connected with the paddle 292. In this way, actuating the door drive mechanism also actuates the retainer mechanism 290. In addition, it can be desirable to bias the retainer mechanism into the extended position or the retracted position. In the present example, a biasing element, such as a spring, biases the paddle toward the retracted position. Figure 17

[0153] Optionally, the connection between the door driver 240 and the paddle 292 is configured so that actuating the door driver from the closed position to the open position drives the paddle from the retracted position to the extended position. In addition, the door driver 240 and the paddle 292 can be connected so that actuating the door driver from the open position to the closed position drives the paddle from the extended position to the retracted position.

[0154] Operation

[0155] The system 10 and various subassemblies described above can be configured to facilitate a number of methods of operation related to material handling as described below.

[0156] The system 10 can include a plurality of autonomous carriers 100 for delivering items to the workstation 200. The carriers can be configured to drive along a horizontal path 60, such as along the ground. Optionally, the carriers can drive along the ground to a storage area where a plurality of items are stored. For example, the plurality of items can be stored in a plurality of containers, such as totes. Optionally, the totes can be stored in a plurality of shelves 20 that are spaced apart to form a longitudinally elongated aisle 50. The aisles can be parallel to each other.

[0157] ​The vehicle 100 can drive under one of the racks 20 in a direction parallel to one of the aisles 50. The vehicle 100 can drive under the rack until the vehicle reaches a destination column 22 in the rack, which is the column in which the item is stored or from which the item is to be retrieved. Optionally, when the vehicle reaches the destination column, the vehicle can rotate or turn to change the direction of travel. For example, the vehicle can change from a direction of travel parallel to the aisle to a direction of travel transverse to the aisle when the vehicle is in the destination column. Alternatively, the vehicle can drive under the rack 20 along a path generally perpendicular to the aisle to the destination column. After reaching the destination column, the vehicle optionally drives perpendicular to the aisle into the aisle of the destination column.

[0158] In the aisle, the vehicle optionally drives upward to a destination location 25 at which the item is stored or from which the item is to be retrieved. The vehicle can be raised upward along the column by an elevator or other mechanism. However, in the present example, the vehicle includes a vertical drive mechanism 140 that can be used to drive the vehicle upward. In addition, the system can include a rail or guide 40 positioned adjacent to the column, and the vertical drive of the vehicle can engage the rail or guide to drive the vehicle upward along the column to the destination location.

[0159] After the vehicle is raised to the destination location, the item, such as a tote 55, can be transferred between the vehicle and the destination location. For example, the vehicle can include a transfer mechanism for transferring the tote, and the vehicle can actuate the transfer mechanism to transfer the tote from the vehicle to the destination location or from the destination location to the vehicle.

[0160] After the item is transferred between the vehicle and the destination location, the vehicle optionally drives downward to a horizontal path, such as the floor. The vehicle can then drive horizontally along a path that is perpendicular to the aisle.

[0161] The system can also include one or more workstations 200. The system can include a method for operating an autonomous vehicle at the workstation 200. For example, the vehicle 100 can travel along a horizontal path carrying an item, such as a tote 55, to the workstation 200. The vehicle can drive into the workstation to align the vehicle with a predetermined location within the workstation. Alternatively, the vehicle can drive through the workstation to another workstation. For example, the workstation can include a plurality of locations referred to as pick locations. The vehicle can drive through the workstation to move from a first pick station 205 to a second pick station. Alternatively, the vehicle can drive into the workstation, drive through the workstation, and then exit the workstation to move to a different workstation in which the vehicle is to present the item for removal.

[0162] The system can optionally include a method for controlling a carrier to submit an article, such as a totes, at a workstation 200. For example, the method can include the step of driving the carrier 100 into the workstation 200 and raising the carrier upward. For example, the carrier can be raised upward toward an operator. Optionally, the workstation can include an opening in the upper surface, and the method can include the step of raising the carrier such that a tote on the carrier is positioned within the opening. Further, the opening can be configured to correspond to an interior configuration of the tote. Moreover, the step of raising the carrier can include the step of raising the tote until an upper edge of the tote is adjacent to a lower side of the upper surface and an interior of the tote is aligned with the opening. Yet further, the step of aligning the tote can include positioning the tote such that the interior of the tote substantially spans the opening to enclose the opening to impede articles from passing through the opening and out of the tote.

[0163] The method of controlling a carrier to submit an article can optionally include the step of tilting the tote as it is raised. For example, the method can include the step of raising the carrier vertically upward and gradually displacing the carrier relative to the horizon such that a first edge of the carrier is raised relative to a second edge of the carrier. Optionally, the step of raising the carrier vertically upward can include the step of tilting the carrier until the carrier is tilted to a predetermined angle relative to the horizon and then raising the carrier vertically upward at the predetermined angle. Optionally, depending on the characteristics of the article carried by the carrier, the system can selectively control the carrier to raise vertically at the predetermined angle for a distance. Specifically, if the article is a first height, the carrier can travel a first distance at the predetermined angle. If the article is a second height, the carrier can travel a second distance greater than the first distance at the predetermined angle.

[0164] The predetermined angle to which the carrier is raised can correspond to an angle of an upper surface of the workstation such that the carrier is tilted to an angle that is substantially parallel to an opening in the upper surface. Further, the system can be configured to accommodate totes or containers of different heights at the workstation. For example, the carrier can be raised and tilted to a predetermined height and then raised at the predetermined angle for a first distance for a tote having a first height. Similarly, the carrier can be raised at the predetermined angle for a second distance for a tote having a second height. Preferably, in both instances, the carrier is raised such that an upper edge of the tote is adjacent to an upper surface of the workstation.

[0165] Optionally, the step of raising and tilting the vehicle 100 can include a step of driving the vehicle upward along the track 250. The track can include a pair of spaced apart curved forward track segments and a pair of spaced apart curved rear track segments. The method can include a step of driving the rearward edge of the vehicle at a higher velocity to raise the rearward edge of the vehicle relative to the forward edge of the vehicle to tilt the vehicle to a predetermined angle. After tilting the vehicle to the predetermined angle, the method can include a step of driving the rearward edge of the vehicle along the rearward track at a velocity substantially similar to the velocity of driving the forward edge of the vehicle along the forward track. Additionally, the step of driving the vehicle upward along the track can include a step of driving the forward edge of the vehicle upward along a first section of the forward track having a first gear tooth spacing and driving the forward edge of the vehicle upward along a second section of the forward track having a second gear tooth spacing.

[0166] Optionally, the step of driving the vehicle 100 upward along the track 250 can include a step of rotating the vertical drive gear 145 of the vehicle about an axis transverse to the rotational axis of the plurality of drive elements driving the vehicle along the horizontal surface. The step of driving the vehicle upward along the track can include a step of driving the vertical drive gear in a first direction to drive a drive gear 330 engaged with the track 250. Driving the vertical gear in the first direction drives the drive gear upward along the track. The drive gear can have a first gear element having a first gear spacing and a second gear element having a second gear spacing. The method can include a step of driving the vertical drive gear 145 to drive the first gear element upward along a first section of the track and continuing to drive the vertical drive gear 145 to drive the second gear element upward along a second section of the track.

[0167] The system can optionally include a method for charging an autonomous material handling vehicle. The method can include a step of driving the vehicle 100 into a work station 200 to deliver an item. The vehicle can include electrical contacts 160 and the work station can include a charging element 340 for providing a charging current. The method can include a step of electrically connecting the electrical contacts 160 of the vehicle with the charging element 340. For example, the step of connecting can include a step of biasing the charging element toward the charging contacts and / or a step of biasing the charging contacts toward the charging element.

[0168] Additionally, the method of connecting can include a step of driving the vehicle toward the charging element to drive the electrical contacts 160 into electrical connection with the charging element 340. Optionally, the method includes a step of automatically adjusting the height of the charging element 340 relative to the charging contacts 160 as the charging contacts are displaced into electrical engagement with the charging element. Additionally, the method can include a step of automatically adjusting the lateral positioning of the charging contacts relative to the charging element as the charging contacts are displaced into electrical engagement with the charging element.

[0169] The method of charging a vehicle can optionally include the step of vertically raising the vehicle while continuing to charge the vehicle. For example, the method can include the step of maintaining electrical engagement between the electrical contacts 160 of the vehicle and the charging elements 340 as the vehicle is displaced upwardly. Further, the charging current can be continuously provided to the charging elements as the vehicle is displaced upwardly at the workstation 200. Additionally, the charging current to the charging elements can be maintained as the vehicle remains at the picking station 205 of the workstation 200 so that the charging current can be supplied to the vehicle as an operator transfers items to or from the vehicle. The charging current can also be supplied to the vehicle as the vehicle is lowered downwardly. The method can optionally include the step of disengaging the vehicle from the charging elements 340 by driving the vehicle away from the charging elements.

[0170] The system optionally includes a method for delivering and holding containers at the workstation 200. For example, the method can include the steps of driving a vehicle carrying a container, such as a tote, to the workstation and raising the vehicle to raise the container at the workstation. As the tote is raised at the workstation to a predetermined height, a holder can hold the tote at the predetermined height as the vehicle moves away from the workstation. For example, the tote can be held at the predetermined height as the vehicle is lowered downwardly and then driven along a horizontal path away from the workstation. While the tote is held after the vehicle is displaced away from the tote, the method can optionally include the step of selectively accumulating a plurality of items into the tote.

[0171] Optionally, the items accumulated in the tote can be delivered by one or more separate vehicles. For example, the workstation 200 can include a plurality of adjacent picking stations 205 and each picking station can be configured to receive a vehicle to deliver items to the workstation. The tote 55 can be held in a raised position by a holder 290 at a first picking station 205 of the workstation. As the tote is held at the first picking station, a vehicle can deliver items to a second picking station. An operator can remove the items from the vehicle at the second picking station and place the items into the tote at the first station. The process of the vehicle delivering items to the second picking station to provide items to be placed into the tote at the first picking station can continue until a predetermined set of items are placed into the tote at the first picking station.

[0172] Once the predetermined set of items have been accumulated in the tote at the first picking station, the tote can be removed from the first picking station. Optionally, the tote can be removed by driving a vehicle into the workstation and raising the vehicle upwardly toward the tote. The holder can then be disengaged from the tote to release the tote. The vehicle can then be displaced downwardly with the tote. The vehicle can then be driven away from the workstation to drive the tote of accumulated items away from the workstation 200. It should be understood that the vehicle that extracts the tote from the first picking station can be different than the vehicle that delivers the tote to the first picking station.

[0173] Similarly, the method can include the step of removing the items from the held tote and feeding the items to a plurality of totes at one or more individual pick stations, rather than accumulating the items in a tote held at a pick station. For example, a tote held at a first pick station can contain a plurality of items. At one or more adjacent pick stations, a plurality of carriers can deliver a plurality of totes to the adjacent pick stations. As each tote is delivered, an operator can remove one or more of the items from the tote at the first pick station and transfer the items to a tote delivered to an adjacent pick station. In this way, the tote delivered to the first pick station can provide a supply of items to be transferred to one or more totes delivered to one or more adjacent pick stations. After transferring items from the tote held at the first pick station, the method can include the step of raising the carrier in the first pick station and releasing the holder to release the tote. The carrier can then be lowered down with the tote, and the carrier can be driven away from the workstation with the tote. It should be understood that the carrier that extracts the tote from the first pick station can be different than the carrier that delivers the tote to the first pick station.

[0174] Optionally, the system can also include a method for selectively enclosing the opening 216 in the upper surface 215 of the workstation 200. A covering, such as a door 230, can be displaced over the opening 216 of the workstation 200 to obstruct the passage of items through the opening. When the covering overlies the opening, the carrier that carries the tote can be raised so that the top edge of the tote is at a determined height proximate to the upper surface 215. After the tote is at the predetermined height, the cover plate can be removed from the opening to provide access to the tote through the opening. In response to a signal that the transfer of items to the tote or the transfer of items from the tote has been completed, the central controller 90 can control the operation of the door to displace the covering over the opening. For example, the controller can actuate a drive mechanism to close the door 230 over the opening 216. In addition, the central controller can control the operation of the carrier to hold the carrier in the raised position to maintain the tote at the predetermined height until the door is closed over the pick opening. After the door is closed, the central controller can provide a signal to the system to lower the carrier with the tote and then move the carrier away. For example, the central controller can provide a signal to the carrier to drive the carrier down to lower the carrier.

[0175] The system can optionally provide a method for adjusting the vertical drive 140 relative to the workstation 200 to provide a gap between the vertical drive and the workstation when the carrier is driven into the workstation. The carrier can be driven into the workstation so that the teeth of the vertical drive gear pass through the teeth of the element that cooperates with the vertical drive gear to drive the carrier upward. Driving the vertical drive gear in a first direction drives the carrier upward in the workstation. Driving the vertical drive gear in a second direction drives the carrier downward.

[0176] To prevent the vertical drive gears from impacting the workstation when the vehicle is driven into it, the position of one or more teeth of each vertical drive gear can be monitored to ensure that the teeth are in a predetermined position relative to the workstation. Specifically, the method may include the step of monitoring the circumferential position of a predetermined tooth of each vertical drive gear 145. The vehicle may enter the workstation and be driven upward and then downward. After the vehicle is driven downward to the ground, the position of the predetermined tooth of each vertical drive gear can be measured relative to the workstation. For example, the workstation may include a gear meshing with each vertical drive gear. Optionally, such a gear may be a transmission gear 330. After the vehicle is lowered to the ground, the position of the predetermined tooth of each vertical drive gear can be detected to determine whether the tooth is within a predetermined circumferential range. The circumferential range can be determined relative to the tooth spacing of the gear meshing with the vertical drive gear to ensure that the vertical drive gear does not impact the meshing gear when the vehicle is driven parallel to the axis of rotation of the meshing gear.

[0177] The system may also include methods for projecting information onto workstation 200 to assist an operator in handling items. For example, a container of transport box 55 may be moved into opening 216 in workstation 200. A surface may be provided adjacent to opening 216. For example, the surface may border all or part of the opening. Figure 19 In the example shown, surface 215 optionally surrounds the entire opening 216.

[0178] The projector 220 can be controlled to provide one or more projections onto the workstation to provide information to assist the operator. For example, the projector can provide a first light signal to indicate to the operator the item to be retrieved. For example, the first light can illuminate the item to be retrieved in the transport container. The transport container 55 may include multiple dividers that divide the transport container into multiple individual storage locations, referred to as units 56. The projector can direct the first light 400 onto a specific unit 56, such that the unit is illuminated while the remaining units are not illuminated, such as... Figure 19 As shown in the image. In this way, the first light signal can identify the location of the item to be retrieved.

[0179] Projector 220 may optionally provide a second light to provide the operator with information about the item to be retrieved. For example... Figure 19 As shown, the second optical signal 405 can be projected onto the surface 215 of the workstation 200 adjacent to the opening 216 in the workstation. Optionally, the second optical signal can be projected onto the surface adjacent to the location of the item contained in the transport container. For example, as Figure 19 As shown, the second optical signal 405 can be projected onto the surface 215 adjacent to the first optical signal 400.

[0180] The second optical signal can provide any of a variety of information to assist the operator in retrieving one or more items. For example, such as...Figure 19 As shown in the middle, the second light signal can identify the number of items to be extracted from the tote.

[0181] The method can also include a step of projecting a third light signal to provide the operator with additional information about the item to be extracted. Depending on the configuration of the surface 215 and the configuration of the second light signal and the third light signal, the third light signal 410 can be projected onto the surface 215 adjacent to the first light signal and / or adjacent to the second light signal 405. The third light signal can be configured to provide different information than that provided by the second light signal 405. For example, as shown in the right image, Figure 19 As shown in the middle, the second light signal can identify the number of items to be extracted from the tote.

[0182] As described above, the projector can be configured to project multiple signals onto the items in the tote 55 or onto the work surface 215 adjacent to the tote. It should be understood that the projected visual signals can differ in number and configuration. For example, Figure 19 The embodiment is shown providing three different types of light signals: a first light signal identifying the location of the item, a second light signal identifying the number of items to be extracted, and a third light signal identifying the item to be extracted. However, in some applications, different information can be provided, or only one or two of the light signals can be utilized. Similarly, additional light signals can be projected onto the tote 55 or onto the surface 215 of the workstation 200 adjacent to the tote.

[0183] In this way, the system can provide a method of handling items, including the steps of extracting a container of items and transferring the items to the workstation 200. The method can include the step of projecting a first light signal onto a portion of the container to identify a location from which an item is to be extracted from the container. The method can include the step of simultaneously projecting a second light signal onto the surface 215 of the workstation, the second light signal identifying a number of items to be extracted from the identified location within the container. Optionally, the method can include the step of projecting a third light signal onto the surface 215 of the workstation 200 identifying the item to be extracted. The third light signal can be provided instead of the second light signal, or the third light signal can be provided simultaneously with the second light signal.

[0184] The method can also include the step of actuating an actuator to indicate that the appropriate item has been extracted from the container. The actuator can be any of a variety of actuators, such as a button or a touch screen display. In response to actuating the actuator, the container can be displaced away from the workstation. For example, the container can be displaced away from the workstation by one of the carriers 100.

[0185] Therefore, it is to be understood that the present application is not limited to the specific embodiments described herein, but rather only limited by the scope and spirit of the invention, as expressed in the appended claims.

Claims

1. A method for delivering items from a storage system to a picking station, comprising the following steps: Drive the container-carrying vehicle to the picking station; The carrier is driven upward at the picking station to an upper position to move the container to a raised position to deliver the container to the operator; The container is releasably held in the raised position; When the container is held in the raised position, the carrier is driven downward away from the upper position, thereby separating the carrier from the container when the container is held in the raised position; While the container is held in the raised position, one or more subsequent vehicles are driven to the picking station to deliver items to be placed in the container.

2. The method according to claim 1, comprising the following steps: While the container is held in the raised position, the extraction carrier is driven upward to the upper position at the picking station to operatively engage with the container; as well as Release the container.

3. The method of claim 2, further comprising the step of driving the extraction vehicle downward together with the released container.

4. The method of claim 3, further comprising, after the step of driving the vehicle downward, driving the extraction vehicle horizontally away from the picking station.

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