System and method for providing mobile shuttle load handling system

Abstract

An object handling system (10) is disclosed, comprising at least one automatic moving shuttle (14) comprising: a moving chassis unit (40) for moving the automatic moving shuttle in a first direction; a payload (50) for supporting at least one object thereon, the payload comprising a plurality of prongs (26); and a payload translation system (52) for translating the payload in at least a second direction towards the receiving surface, the at least second direction being orthogonal with respect to the first direction, the payload translation system specifying that the plurality of prongs are adapted to engage a recessed area within the receiving surface.

Description

[0001] priority

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 388,169 filed on July 11, 2022, U.S. Provisional Patent Application No. 63 / 462,434 filed on April 27, 2023, and U.S. Provisional Patent Application No. 63 / 463,131 filed on May 1, 2023, the disclosures of each of which are hereby incorporated by reference in their entirety. Background Art

[0003] The present invention relates to automatic storage / retrieval systems (ASRS) and other object handling systems for objects such as articles, products, packages and other stock keeping units (SKU) pieces, and totes, cases and boxes containing such articles, products, packages and SKUs. The present invention particularly relates to ASRS systems that require long-term and medium-term storage (low throughput to storage ratio) and short-term storage (high throughput to storage ratio), such as where the storage is turned over daily. Long-term and medium-term storage systems require access to a large number of storage locations, while short-term storage systems require rapid access to storage locations.

[0004] Certain existing ASRS and other handling systems are limited by the payload they can reliably store and pick up. Reliability is a core requirement because oftentimes, failures within the system require human intervention which has conflicting priorities such as speed, safety, cost, and complexity. Failure to achieve very low overall system downtime and very short MTTR (mean time to repair) greatly impacts local throughput and has a knock-on effect on the efficiency of other parts of the system. Storage and retrieval systems are often the primary source of buffering, while other system buffers are kept short.

[0005] For example, shuttle and lift systems, stacker systems, and tower robot systems are becoming more common and offer many benefits over more traditional crane-based systems in terms of system-level throughput and tolerance to single points of failure, but without limiting the system to a large scale. Some of these systems also work well with conventional bin (or pallet) based storage, which allows the payload interface to have consistent design features in the payload acquisition and storage bins. For example, payload handling in these systems ranges from a controlled lift style with paired bottom locating features to an engaged drag style that can be pulled from greater distances via side engaging pockets (arguably the most common) using extensions behind the pulling fingers to pull.

[0006] Some of these systems involve reaching behind objects and suggest compatibility with regular rectangular base cardboard boxes. However, applicants have found that, for various reasons, such compatibility is not always reliable, and sometimes it is necessary (for reliability reasons) to place the box in a box or suitcase. In addition, these existing systems have difficulty handling unboxed bulk items that could otherwise be conveyed (e.g., shrink-bound beverage cartons, dog food bags, cat litter, etc.).

[0007] Therefore, there remains a need for more powerful, efficient, and economical ASRS and other object handling systems that need to access objects of various geometries in long- to medium-term storage as well as in short-term storage requiring high turnover rates. Summary of the invention

[0008] According to one aspect, the present invention provides an object handling system, comprising at least one automated mobile shuttle, the at least one automated mobile shuttle comprising: a mobile chassis unit for moving the automated mobile shuttle in a first direction; a payload for supporting at least one object thereon, the payload comprising a plurality of tines; and a payload translation system for translating the payload in at least a second direction toward a receiving surface, the at least second direction being orthogonal to the first direction, the payload translation system providing for the plurality of tines to be adapted to engage a recessed area within the receiving surface.

[0009] According to another aspect, the present invention provides an object handling system including at least one automated moving shuttle. The object handling system includes: a mobile chassis unit for moving the automated moving shuttle in at least one direction; a payload for supporting at least one object on a payload surface, the payload surface including a first payload surface portion and a second payload surface portion; and a segmented payload lifting system for independently raising and lowering the first payload surface portion or the second payload surface portion along a third direction, the third direction being orthogonal relative to the at least one direction.

[0010] According to a further aspect, the present invention provides a method for handling a payload of an automated moving shuttle. The method includes: providing a mobile chassis unit for moving the automated moving shuttle in at least one horizontal direction; supporting at least one object on a payload surface of the payload, the payload surface including at least one tine; moving the payload in a second horizontal direction such that the at least one tine moves between crests of a corrugated storage shelf of the object handling system; and independently raising and lowering the first payload surface portion or the second payload surface portion along a third vertical direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The following description may be further understood with reference to the accompanying drawings, in which:

[0012] Figure 1 An illustrative diagrammatic view of an object handling system including a plurality of mobile shuttle units, each mobile shuttle unit being associated with a level of a shelving system, according to an aspect of the present invention is shown;

[0013] Figure 2 Shows Figure 1 illustrative diagrammatic side elevation view of a mobile shuttle unit;

[0014] Figure 3 Shows Figure 2 An illustrative diagrammatic elevational end elevation view of a mobile shuttle unit;

[0015] Figure 4 Shows Figure 2 an illustrative diagrammatic exploded view of a mobile shuttle unit;

[0016] Figure 5 Shows Figure 2 An illustrative diagrammatic front view of a mobile shuttle unit of with the tines in a lowered position;

[0017] Figure 6 Shows Figure 2 An illustrative diagrammatic front view of a mobile shuttle unit of with the tines in a raised position;

[0018] Figure 7 Shows Figure 6 An illustrative diagrammatic front view of a mobile shuttle unit of , wherein the payload is rotated 90 degrees;

[0019] Figure 8 Shows Figure 6 An illustrative diagrammatic front view of a mobile shuttle unit of , wherein the payload is rotated 180 degrees;

[0020] Fig. 9A and Fig. 9B Shows Figure 2 An illustrative enlarged view of a mobile shuttle unit with the fork tines lowered ( Fig. 9A ) and the tines are raised ( Fig. 9B );

[0021] Fig.10 Shows Figure 8 an illustrative diagrammatic view of a mobile shuttle unit of FIG. 1 with a payload extending above a shelf;

[0022] Fig.11 An illustrative diagrammatic view of a cam lift system used in a mobile shuttle unit is shown, showing the cam pushing the rocker downward, thereby lifting the tines upward;

[0023] Fig.12 Shows Fig.11 an illustrative diagrammatic view of a cam lift system of wherein the cam is rotated so that the rocker is raised, thereby allowing the tines to rest in a lowered position;

[0024] Fig.13 Shows Fig.11 An illustrative diagrammatic view of a cam lifting system of , wherein one cam pushes a first rocker downward, thereby lifting a first set of tines upward, and another cam is shown rotating, causing another rocker to raise, thereby allowing a second set of tines to rest in a lowered position;

[0025] Fig.14 Shows Fig.13 an illustrative diagrammatic side view of a mobile shuttle unit of with one set of tines raised and one set of tines lowered;

[0026] Fig.15 An illustrative diagrammatic exploded view of a payload portion of a mobile shuttle unit including a suspension cam system according to another aspect of the present invention is shown;

[0027] Fig.16 Shows Fig.15 an illustrative diagrammatic view of a payload portion of the embodiment of the present invention with the tines in a lowered position;

[0028] Fig.17 Shows Fig.15 an illustrative diagrammatic view of a payload portion of the embodiment of the present invention with the tines in a raised position;

[0029] Fig.18 Shows Fig.15 an illustrative diagrammatic view of a payload portion of a device with one set of tines in a raised position and one set of tines in a lowered position;

[0030] Fig.19 Shows adjacent shelving system Fig.17 An illustrative diagrammatic view of a mobile shuttle unit;

[0031] Fig. 20 Shows Fig.19 an illustrative diagrammatic view of a mobile shuttle unit of the rack system with a payload extending above the racks of the rack system;

[0032] Fig.21 An illustrative diagrammatic view of a mobile shuttle unit including bi-directionally extendable payload tines according to another aspect of the present invention is shown;

[0033] Fig. 22 Shows Fig.21 An illustrative diagrammatic exploded view of a mobile shuttle unit of FIG. 1 with a mobile bridge located at a first end;

[0034] Fig.23 Shows Fig.21 an illustrative diagrammatic exploded view of a mobile shuttle unit of the invention with a mobile bridge located at an opposite second end;

[0035] FIG. 24A to FIG. 24D Shows Fig.21 An illustrative diagrammatic view of a mobile shuttle unit of FIG. 1, showing the payload not extended ( Fig.24A ), showing that the effective load extends in the first direction ( Fig. 24B ), showing that the mobile bridge has moved to Fig. 22 The opposite side ( Fig.24C ), and shows that the payload extends in an opposite second direction ( Fig.24D );

[0036] Fig.25A and Fig.25B Shows Fig.21 An illustrative diagram of the fork tines of the mobile shuttle unit's payload is enlarged, showing the fork tines prior to transfer ( Fig.25A ) and rollers on the ends of the tines supported by the mobile shuttle unit after transfer, wherein the rollers contact a lower surface within the shelving system ( Fig.25B );

[0037] FIG. 26A to FIG. 26D An illustrative diagrammatic view of a mobile shuttle unit including a payload position adjustment system according to a further aspect of the present invention is shown, showing an object in a first position on a payload ( Fig.26A ), showing that the object has moved to a second position on the payload ( Fig.26B ), showing that the object has been transferred to the first position on the shelving system ( Fig.26C ), and another object is shown transferred to a second position on the shelving system that is forward of the first position ( Fig.26D );

[0038] Fig. 27 Shows Fig.21 An illustrative diagrammatic lower side view of a translation system of a mobile shuttle unit;

[0039] Fig.28 Shows Fig. 27 An illustrative diagrammatic lower side view of the translation system of , wherein the bridge has begun to move to the opposite end of the mobile shuttle unit;

[0040] Fig.29 Shows Fig. 27 an illustrative diagrammatic side view of a translation system of with the tines raised and the bridge at a first end;

[0041] Fig.30 Shows Fig.29an illustrative diagrammatic side view of a translation system of with the tines lowered and the bridge at a first end;

[0042] Fig.31 Shows Fig.29 An illustrative diagrammatic side view of the translation system of wherein the bridge has been moved to the opposite sending end;

[0043] Fig.32 Shows Fig.29 an illustrative diagrammatic side view of a translation system of with the bridge at the second end and the tines raised;

[0044] Fig.33 Shows Figure 1 An illustrative diagrammatic end elevation view of a system of showing a lift platform for vertically moving an object;

[0045] Fig.34 Shows Fig.33 An illustrative diagrammatic elevational end elevation view of a system of wherein the lift platform has moved an object vertically to a set of elevated shelves;

[0046] Fig.35 An illustrative diagrammatic side elevation view of a system including an autonomous moving vehicle according to another aspect of the present invention is shown;

[0047] Fig.36 Shows Fig.35 An illustrative illustration of an autonomous mobile vehicle approaching a vertical structure is shown in an enlarged side view;

[0048] Fig.37 Shows Fig.36 An illustrative diagrammatic view of an autonomous mobile vehicle having entered a vertical configuration;

[0049] Fig.38A and Fig.38B Shows Fig.37 An illustrative diagrammatic exploded view of an autonomous mobile vehicle of Fig.38A ) and exploded end view ( Fig.38B );

[0050] Fig.39A and Fig.39B Shows Fig.37 An illustrative diagrammatic side view of an autonomous mobile vehicle of FIG. 1, showing the vehicle in a position for vertical engagement ( Fig.39A ) and vertical joint vertical structure ( Fig.39B ) is an autonomous mobile vehicle centrally located on a

[0051] Fig.40 Shows Fig.37 an illustrative diagrammatic exploded view of an autonomous mobile vehicle of having been raised to an elevated position in a vertical configuration;

[0052] FIG. 41A to FIG. 41C Shows Fig.40 An illustrative enlarged view of an autonomous mobile vehicle of FIG. 1 showing a mobile shuttle unit approaching an autonomous mobile vehicle ( Fig.41A ), showing that the mobile shuttle unit has engaged an object on the automated moving vehicle ( Fig.41B ), and the mobile shuttle unit is shown having towed the object from the automated moving vehicle onto the mobile shuttle unit ( Fig.41C );

[0053] Fig.42A and Fig.42B Shows Fig.40 An illustrative enlarged view of a portion of an autonomous vehicle showing a support structure ( Fig.42A ) and showing the support structure elevated relative to the base ( Fig.42B );

[0054] Fig.43A and Fig.43B An illustrative, enlarged view of a portion of a self-moving vehicle including a vertical linear drive system according to another aspect of the present invention is shown, showing a support structure ( Fig.43A ) and showing the support structure elevated relative to the base ( Fig.43B );

[0055] Fig.44A and Fig.44B An illustrative, enlarged view of a portion of an autonomous moving vehicle including a cam lift system according to another aspect of the present invention is shown, showing a support structure ( Fig.44A ) and showing the support structure elevated relative to the base ( Fig.44B );

[0056] Fig.45 An illustrative diagrammatic side view of an object handling system including a plurality of vertical structures operable to store objects according to further aspects of the present invention is shown;

[0057] Fig.46 Shows Fig.45 An illustrative top view of an object handling system;

[0058] Fig.47 Shows Fig.45 an illustrative diagrammatic end view of an object handling system of;

[0059] Fig.48 Shows Fig.45An illustrative diagram of a portion of an object handling system of FIG. 1 is an enlarged side view of the object handling system;

[0060] Fig.49 An illustrative diagrammatic view of an object handling system according to another aspect of the present invention is shown, the object handling system including a plurality of handling conveyors to feed objects in place of a lifting system at a shelf system;

[0061] Fig.50 Shows a portion of the mobile shuttle unit payload engaged Fig.49 An illustrative enlarged view of a portion of a plurality of process conveyors;

[0062] Fig.51 Shows Fig.15 Engagement of a portion of the payload of the mobile shuttle unit Fig.49 an illustrative, schematic, enlarged view of a portion of a plurality of process conveyors of; and

[0063] Fig.52 An illustrative diagrammatic view of an object handling system according to another aspect of the invention is shown, the object handling system including a plurality of handling conveyors for providing objects to any of a plurality of mobile shuttle units in place of a lift system at a shelving system.

[0064] The drawings are for illustration purposes only. DETAILED DESCRIPTION

[0065] The present invention provides an automated mobile shuttle for use in an ASRS or other object handling system. According to one aspect, the automated mobile shuttle includes, for example: a mobile base unit for moving the automated mobile shuttle in at least one direction; a payload for supporting at least one object on a payload surface, the payload surface including at least a first payload surface portion and a second payload surface portion; a payload rotation system for rotating the payload around a first axis, the first axis being orthogonal to at least one direction of the payload of the automated mobile shuttle; a payload translation system for translating the payload in at least a second direction, the at least second direction being orthogonal to the first axis; and a segmented payload lifting system for raising and lowering the first payload surface portion or the second payload surface portion along a third direction, the third direction being parallel to the first axis. Thus, according to one aspect, the system provides four main axes of motion, including driven movement of the carrier, rotation of the payload, extension of the payload, and lifting of the payload. As discussed herein, the degrees of freedom between the main axes of motion provide flexibility for providing longitudinal heterogeneous storage.

[0066] The payload handling techniques disclosed herein can be used with autonomous mobile vehicles that move around a work environment by a variety of methods including, for example, track-based systems, rack and pinion, belts and pulleys, cable traction, or any number of other methods with trade-offs between speed, accuracy, cost, complexity, etc.

[0067] Mobile shuttle position feedback (sometimes called localization) can be achieved in a variety of ways familiar to the mobile robotics art, including but not limited to odometry, integrated calculations using inertial feedback from an inertial measurement unit (IMU), unique positioning markers (sometimes called fiducials), non-unique positioning markers with area markers / home positions (e.g., counting pulses from regularly spaced markers), or even fixed-point continuous measurements such as time-of-flight laser sensors or multi-beacon triangulation.

[0068] It is further understood that even if the mobile shuttle is engaged with the rack system, the shuttle (including shuttle lift transport in some cases) may completely leave the rack to perform package exchanges or other operations outside the rack. In addition, the choice of drive should be paired with the choice of positioning technology and the previously mentioned additional mobility outside of the tethered track implementation to achieve the overall system goals.

[0069] According to various aspects, the system provides payload handling versatility using multiple closely spaced tines that are capable of docking with virtually any package that is wider than 2 times the distance between the tines. In addition, the design can be expanded or contracted to accommodate different environments. For example, the tine spacing can be adjusted closer to handle smaller objects or the tine spacing can be adjusted farther apart to handle larger objects. According to one aspect, the shortest dimension of the smallest object is at least 3 inches or 5 inches. Using this aspect, smaller objects can be transported when they are grouped into larger shipping units (e.g., in boxes, cases, pallets, or totes).

[0070] According to a further aspect, the present invention provides a mobile unit payload that includes roller tips that share the load after lifting between rollers resting on the shelf troughs and guides or rollers within the shuttle body during extraction. The same load sharing occurs during shelf insertion and exchange with system level intake and exhaust equipment. This strategy of providing support from both ends has important implications for component selection for a given load.

[0071] Figure 1A system 10 is shown that includes a plurality of shelves 12 arranged in two mutually opposing arrays with a plurality of mobile shuttle units 14 between the plurality of shelves. Each mobile shuttle unit can receive objects at a processing end 16 of the system, move along a row between a plurality of shelf positions, and provide the objects to any shelf on either side along the row. The mobile shuttle units 14 are also adapted to retrieve objects from the shelves and bring the retrieved objects to the processing end 16 of the system. The system 10 can receive input objects and provide the retrieved objects via an elevator platform 18 that moves between the processing ends of each row (reference will be made below). Fig.35 Examples of which are discussed in the accompanying drawings. Operation of the system (and all systems disclosed herein) may be provided by one or more computer processing systems 100, 200 in communication with the mobile shuttle units and conveyor systems described herein. The position of the mobile shuttle units along the shelves may be determined by any of wheel rotation monitoring, shelf markings, global positioning systems, or remote (wireless) signal detection (such as visual, infrared, echolocation, etc.).

[0072] refer to Figure 2 and Figure 3 Each mobile shuttle unit 14 (according to one aspect of the invention) includes a mobile unit chassis 40 having four wheels 42 (e.g., two of which are powered by motors 41 within the chassis housing) for moving the unit 14 along tracks 44 mounted to the inside of the shelf 12 (e.g., Figures 5 to 10 shown) move. Figure 2 The shuttle carrier 14 is shown from a rear view showing the leading edge of the tines 26, and Figure 3 The shuttle carrier is shown from a front view showing the tines 26 in a raised position. The position of each mobile shuttle unit along the shelf is monitored by a sensor system on the unit 14 and the shelf 12. Further reference is made to Figure 4 The payload 50 including the tines 26 is disposed on a translation system 52 for moving the payload relative to a translation base 54. Specifically, Figure 4 An exploded view of the shuttle carrier 14 is shown showing a payload 50 that travels along a translation system 52 relative to a base 54 and rotates relative to the mobile unit chassis 40 via a gear 56 and a rotation system 58. The base 54 includes an attached gear 56 that is driven relative to the chassis 40 by the rotation system 58. The tines 26 are provided in two sets, each set being mounted for lift movement by an independent lift actuation system 46, 48 (as discussed in more detail below).

[0073] Therefore, according to certain aspects, the system provides for positioning of the shuttle tines 26 so that they are longitudinally aligned with the troughs in the shelves 12 of the racking system. According to further aspects, the system can separate the areas (aisles, vertical levels, longitudinal compartments) of the shelves according to the package size, and the position varies less in the longitudinal direction. In these cases, the tines still have to be aligned, but the one-to-one relationship of the tines to the troughs is not so important, for example, a group of shuttles in a fleet may only see large packages, and the spacing of the payload tines and interfaces can be expanded to 5 times the shelf spacing.

[0074] Figure 5 The tines 26 are shown in a lowered position, and Figure 6 The raised tines 26 are shown, and both figures show the carrier 14 positioned between the shelves 12. In the lowered position, the tines 26 are located at a height below the height of the peaks of the adjacent shelves 12, while in the raised position, the tines 25 are located above the height of the peaks of the adjacent shelves 12. The shelves can take a generally corrugated form with alternating peaks and troughs. The translation system 52 can be engaged to extend the payload into the corrugated shelves 12 (above the shelves or staggered between the peaks) to deposit objects onto the shelves 12 or retrieve objects from the shelves 12. Figure 7 The payload is shown rotated 90 degrees by the rotation system 58 (e.g., for use as described below with reference to Figure 33 to Figure 36 the load or distribution in question), and Figure 8 The payload is shown rotated 180 degrees so that the tines 26 now face the opposing shelf 12 .

[0075] Fig. 9A and Fig. 9B The tines 26 are shown each supported by a flow channel 27, and the flow channels each include one or more guide rollers 29. The corrugated shelf includes peaks 13 and troughs 11, and the flow channels align with and enter the troughs 11 so that the guide rollers 29 enter the troughs 11 of the shelf and begin distributing the load to the shelf during transfer. Fig. 9A The tines 26 are shown in a lowered position below the top height of the shelf surface, while Fig. 9B The tines 26 are shown in a raised position above the top height of the shelf surface. The corrugated shelf may be continuous along the shelf direction (as shown) or may be discontinuous (eg, formed by interrupted U-shaped channels). Fig.10 The payload is shown extended into the shelf 12 by the translation system 52. When an object is placed on the shelf, the payload can be in a raised position (e.g. Fig.10 As shown, the payload may be extended in a lowered position when removing an object from the shelf (and then raised when removing it).

[0076] As mentioned above, the lift actuation systems 46, 48 can be independently actuated to raise the first set of tines ( Fig.14 80) or a second set of fork teeth ( Fig.14 Actuation is provided by a pair of cams 66, 68, one of which (66) may be pushed against a first cam follower 70 of a first rocker base 72, and the other cam may be pushed against a second cam follower 74 of a second rocker base 76. When the rocker base is pushed downward, an associated set of tines is raised. Fig.11 Both cams 66, 68 are shown having been rotated so that both rockers 72, 74 are pushed downward to raise all of the tines. Fig.12 Both cams 66, 68 are shown having been rotated further so that neither rocker 72, 74 engages the cam, causing all tines to be lowered. Fig.13 One cam 68 is shown rotated so that the rocker 74 is pushed downward to raise the associated tine (e.g., 80, as shown in FIG. Fig.14 ), and the differently shaped cam 66 is not in a position to contact the cam follower 70, so the rocker 72 is not lowered and its associated fork teeth (e.g., 82, as shown) are not in a position to contact the cam follower 70. Fig.14 shown) will not rise.

[0077] Therefore, according to Figures 1 to 14 In a system where each mobile shuttle unit provides rotational adjustment of its payload, segmented lift adjustment of its payload, and translational adjustment of its payload. Because the system records where the object is placed, the system always records the position of all objects on the shelf. For example, a payload lift system can be used with a multi-position cam to provide segmented lift of the payload fork. This allows for greater flexibility in handling and placing objects of different sizes on the shelves, eliminating the need for the system to use oversized designated discrete storage locations. Smaller objects can therefore be stored more closely together. This concept can be called longitudinal heterogeneous storage.

[0078] According to a further aspect, the system of the present invention may include a tine set mounted in a cantilevered manner on a lift base as a movable translation system. Fig.15 The mobile shuttle unit 14 ′ (eg Fig.19 and Fig. 20 The upper portion is supported by an attached gear 56 which is rotated by a rotation system 58 which is supported by the mobile unit chassis 40', as described above with reference to Figures 1 to 14 As discussed. Fig.15 As shown, the payload 94 travels along a translation track 96 attached to a translation base 98. The payload 94, track 96, and translation base 98 can be rotated by a rotation system 58 (a portion of which is shown in FIG. Fig.19 and Fig. 20The payload 94 includes a tine 102 extending from one of two suspension mounts 104, 106 that raise and lower the tine 102 (as discussed below). The mounts 104, 106 are suspended from cam mechanisms 110, 112 behind a protective cover.

[0079] like Fig.16 As shown, when the cam mechanisms 114, 116 are rotated so that they do not act on the cam followers 118, 120, the suspension mounts 104, 106 (and the fork tine 102) remain in the lowered position. Fig.17 When the cam mechanisms 114 and 116 rotate so that the cam followers 118 and 120 are pushed upward, the suspension mounts 104 and 106 are also pushed upward, bringing the tines 102 to their raised positions. Fig.18 , when one cam mechanism 114 is rotated so that it contacts cam follower 118 but the other cam mechanism 116 does not contact cam follower 120, one set of teeth (shown at 122) is raised while the other set of teeth (shown at 124) is not raised. Likewise, a payload lift system can be used with a multi-position cam to provide segmented lifting of the payload tines. This allows for greater flexibility in handling and placing objects of varying sizes onto the shelves, eliminates the need for the system to use oversized designated discrete storage locations, and allows smaller objects to be stored more closely together.

[0080] Fig.19 A mobile shuttle unit 14' is shown adjacent to the rack 12. For clarity, only one rack is shown; the unit 14' may be used as described above with reference to Figures 2 to 14 The level in question is set between the rows of shelves. Fig. 20 The tines 102 on seats 104, 106 are shown advancing over the shelf 12. Since the tines 102 are sized to fit between the peaks and valleys of the corrugated shelf 12, the extended tines (when raised / lowered) can be used to place objects onto or remove objects from the shelf 12. Also, since the system records the location of where the objects are placed, the system always keeps track of the location of all objects on the shelf. Again, all operations can be controlled by one or more computer processing systems 100.

[0081] According to a further aspect, the system of the present invention may include a bi-directional translation system that can transfer a payload (or retrieve a payload) from either of two opposing shelves, rather than rotating the payload. Fig.21A mobile shuttle unit 14" is shown that includes a mobile unit chassis 40" having wheels 42 as discussed above. The mobile shuttle unit 40" includes tines 130 mounted on height-adjustable flow channels 132. Each of these tines 13 can be raised and lowered relative to their respective flow channels 132, as described below with reference to Figure 31 to Figure 34 The flow channel 132 is supported by and travels with a bridge 134 (having slidable drive rollers) which is movable between the ends of the mobile chassis unit 40". Fig. 22 An exploded view of the upper portion of the mobile chassis unit is shown with the bridge 134 at one end and Fig.23 An exploded view of the mobile chassis unit is shown, wherein the bridge 134 has been moved to the opposite end.

[0082] The flow channel 132 also travels over support rollers 136, 138 and is supported by these support rollers as the flow channel extends out over the shelf until the roller tips engage the shelf troughs. The support rollers 136, 138 support the load while the bridge 134 drives the flow channel and tines outwardly. Fig.24A A bridge 134 is shown adjacent to one side of the mobile shuttle unit 14", and Fig. 24B The tines 130 are shown extending above the first shelf 12. The bridge 134 can then be moved to the opposite side of the unit 14" (eg, Fig. 24B shown), and Fig.24C A bridge 134 is shown adjacent to the opposite side of the mobile shuttle unit 14". Fig.24D The tines 130 are shown extending above the second shelf 12 .

[0083] and Fig. 9A and Fig. 9B Similar to the system shown in Fig.25A , Fig.25B The tines 130 are shown each supported by a flow channel 132, but the flow channel 132 is bidirectional, having guide rollers 133 at each end thereof. Fig.25A The runner is shown about to engage the lower portion of the shelf, and Fig.25B The runner is shown having engaged the lower portion of the shelf, thereby acting to transfer some of the weight of any load on the runner from the carrier 14 to the shelf. The runner 132 is aligned with and enters the troughs 11 of the corrugated shelf, causing the guide rollers 133 to enter the troughs 11 of the shelf and begin distributing the load to the shelf during transfer. Fig. 24B and Fig.24D The payload is shown extended into the shelf 12 by the translation system 136. The payload may be extended in a raised position when an object is placed on the shelf (and then lowered when removed), or the payload may be extended in a lowered position when an object is removed from the shelf (and then raised when removed).

[0084] The automated shuttle carrier 14 may also include a payload position adjustment system for adjusting the position of an object on the payload receiving portion of the carrier. Fig.26A A carrier 14'' is shown having a payload position adjustment system 150 for adjusting the position of an object 160 on the tines 130. The payload position adjustment system 150 includes a push rod 152 that is movable by a power system 156 via tracks 154 that are attached to a base 158 on the bridge 134. Fig.26B The push rod 152 is shown having pushed the object 160 to a forward position on the tines 130. Fig.26A and Fig.26B In the embodiment of the present invention, the tines 130 are raised to a height sufficient to place the tines 130 above the highest portion of the shelf 12. In this arrangement, the tines 130 can be moved between the corrugations of the shelf to bring the object 160 above the shelf 12. Fig.26C , the push rod 152 is then pulled back to the bridge 134 and the tines 130 are lowered so that the object 160 remains on the distal portion of the shelf. The push rod 152 is first removed and then the support structure is lowered to prevent the push rod 152 from colliding with the shelf. According to a further aspect, the payload position adjustment portion can accommodate changes in the height of the tines 130 relative to the shelf 12. Another object can then be loaded onto the automated moving carrier and moved again to a forward position on the payload receiving surface. Reference Fig.26D , an object 162 may then be similarly deposited on the shelf, but in a proximal position on the shelf. Fig.26A and Fig.26B In the embodiment of the invention, the tines 130 are raised relative to the shelf. Fig.26C and Fig.26D In this way, multiple objects can be positioned at a shelf position that might have been able to receive only one object.

[0085] Fig. 27 and Fig.28 It is shown that under the driving force from the bridge 134, the flow channel 132 travels over the non-actively driven pinion gears 138 (and thereby remains aligned with each other) to extend away from the mobile chassis unit housing. Fig. 27 shows an underside view of the flow channel and pinion, and Fig.28 The bridge is shown having been moved from one side of the carrier. Drive rod 137 engages rack gear 139 on the underside of flow channel 132 to move the tines outward. Pinions 136 and 138 are not actively driven and are used to maintain alignment of the multiple tines. To move in the other direction, bridge 134 (including drive rod) is moved to the opposite side, as shown. Figure 29 to Figure 32Each side of the unit 14" may include bi-directional tines for moving the tines in either of opposite directions (e.g., for accessing opposing shelves 12, as discussed above), and this is achieved without rotating the payload.

[0086] Fig.29 The pointed tooth 130 is shown in a raised position because the cam 140 rotates against the cam block (also used as a linkage, such as using a four-bar linkage) so that when raised or lowered from either end, the tooth 130 rises or falls relative to the flow channel 132, and Fig.30 The teeth 130 are shown in a lowered position because the cam 140 is rotated so that the tines 130 are not raised or lowered relative to the flow channel 132. As discussed above, the cam 140 can be formed of different shapes, and by providing cams of different shapes, different groups of tines can be raised and lowered together or independently. Also as discussed above, the bridge 134 can then be translated to the opposite side of the mobile shuttle unit (such as Fig.31 ), and then the cam 140 can be rotated again so that the tines 130 are again raised and lowered relative to the flow passage 132 (as shown in FIG. Fig.32 136). By moving the bridge 134 (along with the drive rod 137) between the ends of the mobile shuttle 14", the tines can be extended in either of two opposite directions to access a pair of opposing shelves. As the drive rod 137 and bridge 134 are moved between the ends (either under a reciprocating belt drive system or by other linear translation means), the rod is allowed to rotate as it travels along the shelf gear 139 on the underside of the runner 132. When the tines are driven outwardly, the drive rod 137 is rotationally locked. According to a further aspect, the drive rod can be used to maintain alignment of the runners, and the pinions 136, 138 can be used to translationally move the payload.

[0087] refer to Fig.33 and Fig.34 , the system 10 may receive input objects and provide retrieved objects via an elevator platform 18 that moves between the processing ends of each row. Fig.33 The lift platform 18 is shown just being loaded (eg, by a programmable motion device or by a person), and Fig.34 The lift platform 18 is shown raised to the destination level, wherein the shuttle unit 14 engages the object from the lift platform. Likewise, the lift platform and the rack itself are formed of a corrugated platform that allows the tines of the mobile shuttle unit to enter the platform and then rise to engage the object. According to other aspects, the lift platform can be provided by a roller conveyor section that includes rollers spaced a distance that allows the tines to be positioned between (and above) the rollers, as described below with reference to Fig.45As discussed. The objects are conveyed in reverse order using the tines while the objects are held down below the surface. Operation of the system (and all systems disclosed herein) may be provided by one or more computer processing systems 100 in communication with the mobile shuttle units and conveyor systems described herein.

[0088] According to further aspects and with reference to Fig.35 , the present invention provides an object handling system 210, which includes a plurality of automated mobile carriers 212 that are movable toward and upwardly along vertical structures 214 for providing objects to or removing objects from a plurality of levels of shelves 216 via shuttle carriers 218. The shuttle carriers 218 are each disposed on a shelf level (e.g., 220, 222, 224) between a pair of opposing shelves on each level. Navigation of each automated mobile carrier 212 in an environment can be facilitated by unique markers 228 that each carrier 212 uses (via a detection unit on its underside) to confirm the proper position of the carrier, or that are used to instruct the carrier how to adjust its movement to further travel so that the carrier is aligned with the markers 228. According to further aspects, navigation of the automatic mobile vehicle can be provided by any of a variety of technologies, such as wheel rotation counting, camera detection and analysis, 3D scanning detection and analysis, echo positioning and global or local positioning systems. Each automatic mobile vehicle 212 includes two independently operable drive wheels 230, which can move the vehicle in a forward or backward direction, and rotate the vehicle by providing more power to one drive wheel than the other drive wheel or by rotating each drive wheel in mutually opposite directions to rotate the vehicle to the appropriate position. Casters 232 can be used to facilitate holding a hierarchical payload receiving portion 236, on which objects or object boxes can be placed for movement. Payload receiving portion 236 can be formed by a plurality of spaced ribs and supported by support structure 234. Support structure 234 is mounted on a vehicle base 238 (as discussed in more detail below) in an adjustable height.

[0089] The object handling system may be used, for example, in an ASRS system or other object handling system requiring long-term and medium-term storage (low throughput to storage ratio) and short-term storage (high throughput to storage ratio) (e.g., where storage is turned over daily). Long-term and medium-term storage systems require access to a large number of storage locations, while short-term storage systems require rapid access to storage locations.

[0090] Further references Fig.36, the vertical structure includes a plurality of vertically extending lifting gear racks 240, for example, one rack is provided in each of the four corners of the vertical structure 214, and each rack 240 includes a lowermost end 242 that terminates above the floor. The vertical structure 214 may or may not include support legs 244 and a vertical structure base plate 246. The self-propelled vehicle 212 may be driven into the base of the vertical structure 214, and the lowermost ends 242 of the vertically extending lifting gear racks at least pass over the outer portion of the self-propelled vehicle 212. Fig.37 The self-propelled vehicle 214 is shown having entered the base of the vertical structure. The outermost portion of the self-propelled vehicle 212 (at its corner) passes over the lowermost end 242 of the lifting gear rack 240. As described above, the vertical structure can omit the support legs extending upward from the bottom plate and the base plate, wherein the vertical structure includes support members terminating above the bottom plate.

[0091] Further references Fig.38A and Fig.38B , the automated mobile vehicle 212 includes a payload receiving portion 236 that includes support ribs 237 and a rear wall 235 that rise from a floor that provides a floor area 239 . Fig.38A A side exploded view of the autonomous mobile vehicle 212 is shown, and Fig.38B An exploded end view of the self-moving vehicle 212 is shown. The lifting pinions 250 extend beyond the periphery of the payload receiving portion 236. The support structure 34 includes a motor 270 having a drive gear 271 on its shaft. The drive gear 271 drives a first side gear 273, which in turn drives a second side gear. Each of the side gears 273, 275 drives a separate belt 272, and each belt 272 drives a multi-purpose drive shaft 274. Each of the multi-purpose drive shafts is coupled to two lifting pinions 250 (one lifting pinion at each end thereof) and to a pair of base pinions 276.

[0092] The motor 270 is provided as part of the support structure 234. The underside of the vehicle includes one or more sensing systems on its underside for detecting markings on the marker 228. The bi-directional independently operable drive wheels 230 are controlled by motors in the base 238 of the vehicle.

[0093] The self-moving vehicle 212 can readjust its position within the base of the vertical structure 214 by actuating one or both of the independently actuatable bi-directional drive wheels 230. The vehicle 212 can move so that the lift system remains below the lowermost end 242 of the lift gear rack 240 during entry, repositioning, and exit of the vehicle 212 relative to the vertical structure 214. In this way, the vehicle 212 can position itself below the lift gear rack 240 so that the lift gear rack can be engaged by the lift gear 276.

[0094] Reference again Fig.38A , the carrier base 238 includes a chassis 60 having wheels 230, wheel motors 256, and casters 232. The carrier base 238 also includes a base top 262, which includes four base racks 264 extending upward from the base top 262. The base top 262 is fixed to the top of the chassis 260. The support structure 234 includes a support structure base 263 and two multi-purpose drive shafts 274, which are driven by a single motor 270 via a belt 272. Further reference Fig.38B , each multipurpose drive shaft 274 includes two attached base pinions 250 (at its ends) and two attached lift pinions 276. The base pinions 276 (when powered by the motor 70) cause the support structure 234 to climb up the base rack 264 of the carrier base 238, thereby vertically separating the support structure 234 from the carrier base 238.

[0095] Specifically, Fig.39A The carrier 212 is shown at the base of the vertical structure 214, with the support structure 234 of the carrier 212 resting on top of the carrier base 236. Fig.39B When the base pinion 276 is actuated and climbs up the base rack 264, the support structure 234 is vertically spaced apart (lifted away from) the carrier base 236. The degree of separation is controlled by the capped slide bar 278, which maintains a maximum distance between the support structure 234 and the carrier base 238. Continued actuation of the lift pinion 250 (via the motor 270) causes the entire carrier 212 to rise along the lift gear rack 240.

[0096] The motor 270 drives the drive gear 271, which directly drives the side gear 273, which drives the side gear 275. Each of the side gears 273, 275 drives a belt 272, which engages and drives one of the multi-purpose drive shafts 274. Specifically, when the motor is operated in a first direction, the drive gear operates clockwise, the side gear 273 operates counterclockwise, and the side gear 275 operates clockwise. This causes the base pinion on each side to climb up the base rack 264, thereby causing the lifting pinion to contact the lifting gear rack, and subsequent continued rotation causes the lifting pinion 250 to climb up the lifting gear rack 240, thereby causing the carrier 212 to rise along the vertical structure 214. Operating the motor 270 in the opposite second direction causes the lifting pinion to lower the carrier 212 along the lifting gear rack 240 of the vertical structure, and when the base pinion 276 contacts the base rack 264, the support structure 234 is again in contact with the carrier base 238. The capped slide bar 278 terminates separation of the support structure 234 from the carrier base 238 such that continued movement of the support structure 234 (via the lift pinion 250 ) causes the carrier 212 to rise along the lift gear rack 240 .

[0097] When driven by the motor via the belt 272, the base pinion 276 climbs up the base rack 264. The support structure base 263 is initially in contact with the base top 262, and the support structure base slides freely along the capped slide bar 278. As the base pinion 276 approaches the top of the base rack 264, the lifting pinion 250 engages the lifting gear rack 240. As the shaft 274 continues to rotate, the load of the carrier is lifted by the lifting pinion 250 as it climbs up the lifting gear rack 240. As the lifting pinion 250 approaches the lifting gear rack 240, the tapered end of the slide rail 252 facilitates the engagement of the pinion 250 with the rack 240, and as the pinion 240 travels along the rack 240, alignment is maintained at least in part by the slide rail 252 and the free-spinning roller rail 254.

[0098] Reference again Fig.35 Each level of shelves 220, 222, 224 includes a shuttle carrier 218 that moves objects toward and away from the automated moving carrier 212 and toward and away from the shelf 216. Each shuttle carrier 218 is capable of moving along the shelves between two rows of shelves and is capable of rotating its payload receiving portion between positions facing each of two opposing shelves and facing the automated moving carrier 212. For example, Fig.35 The shuttle carrier 218 on level 220 is shown facing the shelf in the foreground, the shuttle carrier 218 on level 222 is shown facing the vertical structure 214, and the shuttle carrier 218 on level 224 is shown facing the shelf on the far side (away from the foreground).

[0099] Each shuttle carrier can receive objects from a mobile carrier 218, move along a row between multiple shelf locations, and provide objects to any shelf on either side along the row. The mobile shuttle carrier 218 is also adapted to retrieve objects from the shelf and bring the retrieved objects to the mobile carrier 218. The system 210 can receive input objects and provide retrieved objects via the mobile carrier 218 that moves between the processing ends of each row. The operation of the system (and all systems disclosed herein) can be provided by one or more computer processing systems 200 that communicate with the mobile shuttle carriers 218 and the automated mobile carriers 212 described herein.

[0100] As discussed above, each mobile shuttle vehicle (according to one aspect of the present invention) includes a vehicle having four wheels (e.g., two of which are powered by motors within the chassis housing, as described above with reference to Figure 3 A mobile unit chassis (described) is used to move the carrier along a track mounted to the inside of the shelf. The position of each mobile shuttle carrier along the shelf is monitored by a sensor system on the carrier and the shelf. A payload receiving portion including tines is provided on the translation system for moving the payload relative to the translation base. The translation base includes an attached gear that is driven relative to the chassis by a rotation system. The tines are provided in two sets, each set of tines being mounted for lifting and lowering movement by an independent lifting actuation system.

[0101] Thus, according to certain aspects, the system provides for positioning of the shuttle tines so that they are longitudinally aligned with the troughs in the shelves of the shelving system. According to further aspects, the system can separate areas of the shelves (aisles, vertical levels, longitudinal compartments) according to package size, and the position varies less in the longitudinal direction. In these cases, the tines still must be aligned, but the one-to-one relationship of the tines to the troughs is not so important, for example, a group of shuttles in a fleet may only see large packages and the spacing of the payload tines and interfaces can be expanded to 5 times the shelf spacing.

[0102] As described above, rotation of the shaft 274 causes the mobile carrier 212 to move upward and downward along the lifting gear rack 240 when driven by the lifting gear 276. Fig.40 The mobile carrier 218 is shown having been raised along the lifting gear rack 240 carrying the object 280 to a position adjacent to the intermediate shelf level 222. Note that the shuttle carrier 218 of the shelf level 222 includes a payload receiving portion having tines 326 that are rotated to face the mobile carrier 212. The tines 326 can be lowered so that when the shuttle carrier 218 approaches the mobile carrier 212, the tines 326 pass between the support ribs 237 of the payload receiving portion 236.

[0103] Fig.41A The fork tines 326 are shown in a lowered position, while Fig.41B The tines 326 are shown raised, thereby transferring the load of the object 280 to the tines 326. Placing the object on the mobile carrier involves the reverse process (raising the tines, moving between the support ribs, and lowering the tines). Fig.41C The object 280 is shown to have been transferred to the mobile carrier 2318 for delivery to a storage location in a plurality of shelves 12. In the lowered position, the fork tine 326 is located at a height below the height of the crests of the support ribs 237 of the adjacent shelves 312 and any adjacent mobile carrier 212. In the raised position, the fork tine 326 is located at a height above the height of the crests of the support ribs 237 of the adjacent shelves 312 and any adjacent mobile carrier 212. The shelf can be in the form of a general corrugation, with alternating crests and troughs. The translation system 352 can be engaged to extend the payload into the corrugated shelf 312 (above the shelf or staggered between the crests) to deposit objects onto the shelf 312 or retrieve objects from the shelf 312. The payload receiving portion 350, translation system 352, and translation base 354 may be rotated 90 degrees in either direction from the center (facing the mobile vehicle 218) via a rotation system 358 (eg, for loading or dispensing relative to the shelf 312).

[0104] Each tine 326 is supported by a flow channel, and each flow channel includes one or more guide rollers. The corrugated shelf includes peaks 13 and troughs 11 (such as Fig. 9B As shown), the flow channels are aligned with the troughs 11 and enter these troughs, so that the guide rollers enter the troughs 11 of the shelf and begin to distribute the load to the shelf during transfer. The corrugated shelf can be continuous along the shelf direction (as shown) or discontinuous (for example, formed by interrupted U-shaped grooves). The payload receiving forks 326 extend into the shelf 312 through the translation system, as discussed above. When an object is placed on the shelf, the payload receiving forks 326 can be extended in a raised position (and then lowered when removed), or when an object is removed from the shelf, the payload receiving forks can be extended in a lowered position (and then raised when removed).

[0105] These tine lift actuation systems are independently actuatable to raise the first set of associated tines and / or the second set of associated tines. Actuation is provided by a pair of cams, one of which is pushed against a first cam follower of the first rocker base and the other cam is pushed against a second cam follower of the second rocker base. Actuation of the cams is provided by a motor system, wherein the cams are mounted on a double-ended shaft. When the rocker base is pushed downward, one set of associated tines is raised.

[0106] Thus, each mobile shuttle unit provides rotational adjustment of its payload, lift adjustment of its payload, and translational adjustment of its payload. Since the system records the location where the object is placed, the system always records the location of all objects on the shelf. For example, a payload lift system can be used with a multi-position cam to provide segmented lifting of the payload forks. This allows for greater flexibility in handling and placing objects of varying sizes on the shelves, eliminating the need for the system to use oversized, designated discrete storage locations. Smaller objects can therefore be stored more closely together. This concept can be referred to as longitudinal heterogeneous storage.

[0107] same, Fig.40 The mobile carrier 212 is shown being lifted as the shuttle carrier 218 approaches the loading area, and Fig.41A The mobile carrier 312 and the shuttle carrier 18 are shown in the loading area. Fig.41A , the tines 326 of the shuttle carrier 218 are lowered and inserted into the payload support portion 236 between the ribs 237. Fig.41B , when the teeth 326 are raised (by the rotation of the cams 366, 368), the object 280 is instead lifted and supported by the teeth 326. Fig.41C As shown, the fork tine 326 is pulled back to the inside of the shuttle carrier 218, so that the payload object 280 is together with them. Then, when the shuttle carrier 218 moves to the specified destination shelf position along the track 344, the fork tine 326 can be lowered or (preferably) maintained in the raised position. Then, the rotation system 352 is engaged to rotate the payload, so that the free end of the fork tine 326 is aligned with the destination position shelf (which is any one of the opposite side shelves 312). The shuttle carrier 218 turns to the first side frame 312 for moving the object 80 to the right side (as shown in the figure) shelf. The shuttle carrier 218 turns to the left side (as shown in the figure) shelf 312, and the raised fork tine has been moved to the left shelf for moving the object 280 to the second opposite side shelf.

[0108] Fig.42A , Fig.42BAn automatic moving vehicle 410 according to another aspect of the present invention is shown, which includes a support structure 412 having a payload receiving portion 414 that can be raised and lowered relative to a vehicle base 418, optionally (at least partially) guided by a capped slide 416. Once raised, a lifting pinion 420 engages a lifting gear rack of the vertical structure and moves along the vertical structure under the guidance of the sliding guide 122 and the roller guide 124, as discussed above. The vehicle 410 also includes a screw drive system 430 (e.g., a four-screw drive or a ball screw system). Each screw drive system 430 includes a screw 432 and a mating drive nut 434 (e.g., threaded or provided with bearings that act as threads). The drive nut 434 is fixed to a support structure base plate 436, and when the screw drive power system rotates each screw 432, the drive nut 434 pushes the support structure base plate 436 (and the entire support structure 412) upward. Reversing the direction of rotation of the screw 432 returns the support structure to a lower position relative to the carrier base 418 . Fig.42A The support structure 412 is shown in a lowered position relative to the carrier base 418, and Fig.42B The support structure 412 is shown in a raised position relative to the carrier base 418. As the support structure 412 is raised, the lifting pinion 420 engages the lifting gear rack of the vertical structure and moves along the vertical structure under the guidance of the slide rails 422 and roller rails 424, as discussed above. In addition, the use of the screw drive system 430 to raise (and lower) the support structure relative to the carrier base is also used to move objects between the carrier and the floor shelf, as described above with reference to Figures 39 to 40. Fig.41C discussed.

[0109] Fig.43A , Fig.43B An automated moving vehicle 440 is shown in accordance with another aspect of the invention, which similarly includes a support structure 412 having a payload receiving portion 414 that can be raised and lowered relative to a vehicle base 418, such as optionally (at least in part) guided by a capped slide bar 416. Once raised, a lift pinion 420 engages a lift gear rack of the vertical structure and moves along the vertical structure under the guidance of the slide rails 122 and roller rails 124, as discussed above. The vehicle 440 also includes linear drive systems 442 (e.g., four linear drive systems). Each linear drive system 442 includes a linear drive rod 446 (e.g., Fig.43B43 (shown in FIG. 4 ), with its distal end 444 fixed to the support structure base plate 436 and its proximal end within the linear drive power control system 448. When the linear drive power system drives the rod 446 upward, the end 444 pushes the support structure base plate 436 (and the entire support structure 412) upward. Reversing the power of the drive power system 448 returns the support structure to a lower position relative to the load-bearing base 418. Fig.43A The support structure 412 is shown in a lowered position relative to the carrier base 418, and Fig.43B The support structure 412 is shown in a raised position relative to the carrier base 418. As the support structure 412 is raised, the lifting pinion 420 engages the lifting gear rack of the vertical structure and moves along the vertical structure under the guidance of the slide rails 422 and roller rails 424, as discussed above. In addition, the use of the linear drive system 442 to raise (and lower) the support structure relative to the carrier base is also used to move objects between the carrier and the floor shelf, as described above with reference to Figures 39 to 40. Fig.41C discussed.

[0110] Fig.44A , Fig.44B An automatic moving carrier 470 according to another aspect of the present invention is shown, which similarly includes a support structure 412 having a payload receiving portion 414 that can be raised and lowered relative to a carrier base 418, as optionally (at least partially) guided by a capped slide bar 416. The side wall portion of the carrier base is removed to illustrate the lifting system discussed below. Once raised, the lifting pinion 420 engages the lifting gear rack of the vertical structure and moves along the vertical structure under the guidance of the sliding guide 122 and the roller guide 124, as discussed above. The carrier 470 also includes cams 474 that abut against followers attached to rocking arms 476. The cams 474 are rotated by a drive system 478. The ends of the rocking arms 476 are attached to crossbars 480, which support sub-support structures 482, which in turn support the support structure 412. Fig.44A Cam 474 is shown rotated so that the rocker is positioned to allow crossbar 480, sub-support structure 482, and support structure 412 to remain in the lowered position. Fig.44BThe cam 474 is shown rotating so that the rocker pushes the crossbar 480 upward, which raises the sub-support structure 482 and the support structure 412. Using the motor 478, the cam is used to raise and lower the support structure 412 relative to the carrier base 418. Similarly, when the support structure 412 is raised, the lifting pinion 420 engages the lifting gear rack of the vertical structure and moves along the vertical structure under the guidance of the sliding guide 422 and the roller guide 424, as discussed above. In addition, the use of the linear drive system 442 to raise (and lower) the support structure relative to the carrier base is also used to move objects between the carrier and the floor shelf, as described above with reference to Figures 39 to 418. Fig.41C As discussed. According to one aspect, the automated moving shuttle includes, for example: a mobile base unit for moving the automated moving shuttle in at least one direction; a payload for supporting at least one object on a payload receiving portion; a payload rotation system for rotating the payload receiving portion about a first axis, the first axis being orthogonal to at least one direction of movement of the automated moving shuttle; a payload translation system for translating the payload in at least a second direction, the second direction being orthogonal to the first axis; and a payload lifting system for raising and lowering any one of the payload surface receiving portions along a third direction parallel to the first axis. Thus, according to one aspect, the system provides four primary axes of motion, including driven movement of the carrier, rotation of the payload, extension of the payload, and lifting of the payload. As discussed herein, the degrees of freedom between the primary axes of motion provide flexibility for providing longitudinal heterogeneous storage.

[0111] Mobile shuttle position feedback (sometimes called localization) can be achieved in a variety of ways familiar to the mobile robotics art, including but not limited to odometry, integrated calculations using inertial feedback from an inertial measurement unit (IMU), unique positioning markers (sometimes called fiducials), non-unique positioning markers with area markers / home positions (e.g., counting pulses from regularly spaced markers), or even fixed-point continuous measurements such as time-of-flight laser sensors or multi-beacon triangulation.

[0112] It is further understood that even if the mobile shuttle is engaged with the rack system, the shuttle (including shuttle lift transport in some cases) may completely leave the rack to perform package exchanges or other operations outside the rack. In addition, the choice of drive should be paired with the choice of positioning technology and the previously mentioned additional mobility outside of the tethered track implementation to achieve the overall system goals.

[0113] According to various aspects, the system provides payload handling versatility using multiple closely spaced tines that are capable of docking with virtually any package that is wider than 2 times the distance between the tines. In addition, the design can be expanded or contracted to accommodate different environments. For example, the tine spacing can be adjusted closer to handle smaller objects or the tine spacing can be adjusted farther apart to handle larger objects. According to one aspect, the shortest dimension of the smallest object is at least 3 inches or 5 inches. Using this aspect, smaller objects can be transported when they are grouped into larger shipping units (e.g., in boxes, cases, pallets, or totes).

[0114] According to a further aspect, the present invention provides a shuttle carrier payload section that includes roller tips that share the load after lifting during extraction between rollers resting on the shelf troughs and guides or rollers within the shuttle body. The same load sharing occurs during shelf insertion and exchange with system level intake and exhaust equipment. This strategy of providing support from both ends has important implications for component selection for a given load.

[0115] As discussed above, vertical lifting structures (e.g., 14, 314) may be provided at the ends of a set of mutually facing shelves (e.g., Figure 1 and Fig. 27 According to a further aspect, the set of shelves may include a vertical lifting structure that is arranged with the shelf or shelves in other arrangements. For example, Fig.45 An object handling system 500 is shown including a group 510 of mutually facing shelves 512, 514. The system 500 includes a first vertical lift structure 516 as described above, and additional vertical lift structures 518, 520, 522. Each of the vertical lift structures 516, 518, 520, 522 is capable of receiving an automated mobile carrier as discussed above with reference to the vertical lift structures 14, 314. Fig.46 A top view of system 500 is shown, and Fig.47 An end view of the system 500 is shown. Using multiple vertical lift structures can increase the throughput of objects in and out of the shelves 512, 514. In addition and as Fig.48 As shown, when the autonomous mobile vehicle is positioned within the vertical lift structure, the vehicle itself can be used as a shelf (eg, when no objects need to be moved). Fig.48 Carriers 530, 532, 534 are shown within vertical lift structures 518, 520, 522, respectively, and are positioned so that their payload receiving portions 540, 542, 544 are flush with a shelf level 546 of shelf 512. The payload receiving portions 540, 542, 544 can be used as shelves (in this manner with automated shuttle carriers 18 ( Fig.46 as shown) until transport is required.

[0116] Fig.49 A system 20 is shown that can receive input objects and provide retrieved objects via any of a plurality of processing conveyors 22, each of which is associated with one of the plurality of levels of rows of shelves. Fig.50 , which shows an enlarged portion of the exchange between the mobile shuttle unit 14 and the processing conveyor 22, with the tines sized to also fit between adjacent rollers 24 of the processing conveyor 22. Similar to the exchange between the mobile shuttle unit 14 and the shelf 12, the mobile shuttle units 14, 14' can retrieve objects from the processing conveyors 22 and place the objects onto these processing conveyors by lowering the tines 26 between the rollers (while holding the objects), and by advancing the tines horizontally between the rollers and then raising the tines to lift the objects from the rollers. This Fig.50 As shown in detail in FIG. 1 , a shuttle unit 14 is used that has a plate 25 that forms a surface (eg, a valley) beneath the rollers 24 against which the guide rollers engage. Fig.51 The shuttle unit 14' is shown positioning the tines 102 between rollers to effect transfer into and out of the conveyor 22. However, it should be appreciated that providing a fixed trough (eg, floor) beneath the rollers allows the system to be more efficient also for shuttle units 14 and 14' having heavy loads due to load sharing.

[0117] Fig.52 A system 30 is shown in which a mobile shuttle unit 14 is capable of receiving objects and providing the objects to a shelf via a processing end that includes a plurality of processing conveyors 32 that are each in line with a shelf 12 and include a mobile unit 15. Each mobile unit 15 is identical to the mobile shuttle unit 14, except that the unit 15 remains in an exchange area to move objects only between the units 14, 15. One side of the conveyor 32 (e.g., the left side of the figure) can be biased (e.g., gravity biased) to push objects thereon toward the shelf 12, while the other side (e.g., the right side of the figure) can be biased (e.g., gravity biased) to push objects thereon away from the shelf 12. Likewise, the processing conveyors 32 include rollers that are sized to allow the tines of the mobile shuttle unit 15 to fit below its top surface so that, as described above with reference to FIG. Fig.50 and Fig.51 As discussed, objects can be moved onto and off of a processing conveyor by a mobile shuttle unit, but the mobile shuttle unit is not required to rotate the payload.

[0118] For example, objects may be received along any one of the processing conveyors 22 that run transversely relative to the racks 12, or may run in a direction generally parallel to the racks 12, such as Fig.52 As shown, wherein objects may be provided from storage along each pair of handling conveyors 32 at each level. According to a further aspect, the conveyor elevators may be used only outside the drop-off area to centralize the various levels into a single entry / exit unloading location.

[0119] Those skilled in the art will appreciate that many modifications and variations can be made to the disclosed embodiments without departing from the spirit and scope of the invention.

Claims

1. An object handling system, comprising at least one automated mobile shuttle, wherein the at least one automated mobile shuttle comprises: a mobile chassis unit for moving the at least one automated moving shuttle in a first direction; a payload for supporting at least one object thereon, the payload comprising a plurality of tines; and A payload translation system for translating the payload in at least a second direction toward a receiving surface, the second direction being orthogonal relative to the first direction, the payload translation system providing that the plurality of tines are adapted to engage recessed areas within the receiving surface.

2. An object handling system as described in claim 1, wherein the receiving surface includes a corrugated surface, the corrugated surface includes peaks and valleys, and the recessed area for engaging the fork tines is provided by the valleys of the corrugated surface.

3. An object handling system as described in claim 2, wherein each tine includes a guide roller for contacting a valley of the receiving surface.

4. An object handling system as described in any one of claims 1 to 3, wherein the payload includes a payload surface, the payload surface including at least a first payload surface portion and a second payload surface portion, wherein the second payload surface portion is capable of independent vertical movement relative to the first payload surface portion.

5. An object handling system as claimed in any one of claims 1 to 4, wherein the object handling system further comprises a payload lifting system for raising and lowering the forks relative to the mobile chassis unit.

6. The object handling system of claim 5, wherein the payload lifting system comprises a cam driven lifting system for lifting at least one end of the first payload surface portion.

7. The object handling system of any one of claims 1 to 6, wherein the object handling system further comprises a payload rotation system for rotating the payload relative to the mobile chassis unit.

8. The object handling system of any one of claims 1 to 7, wherein the plurality of tines are coupled at one end to a cantilever lift system.

9. An object handling system as claimed in any one of claims 1 to 8, wherein the payload translation system includes a bi-directional roller system for extending the payload out of the mobile chassis unit in each of two opposite directions.

10. The object handling system of claim 9, wherein the bi-directional roller system comprises a slidable drive roller.

11. The object handling system of any one of claims 1 to 10, wherein the object handling system comprises a plurality of storage shelves and a plurality of automatically moving shuttles that move between the plurality of storage shelves.

12. An object handling system comprising at least one automated mobile shuttle, the at least one automated mobile shuttle comprising: a mobile chassis unit for moving the automated mobile shuttle in at least one direction; a payload for supporting at least one object on a payload surface, the payload surface comprising a first payload surface portion and a second payload surface portion; as well as A segmented payload lifting system for independently raising and lowering the first payload surface portion or the second payload surface portion along a third direction, the third direction being orthogonal relative to the at least one direction.

13. The object handling system of claim 12, wherein the object handling system further comprises a payload translation system for translating the payload in at least a second direction, the second direction being orthogonal relative to the first axis.

14. The object handling system of any one of claims 12 to 13, wherein the object handling system further comprises a payload rotation system for rotating the payload about a first axis, the first axis being orthogonal with respect to the at least one direction.

15. An object handling system as claimed in any one of claims 12 to 14, wherein the segmented payload lifting system includes a linkage lifting system for lifting the first payload surface portion at each of two opposite ends of the first payload surface portion.

16. An object handling system as claimed in any one of claims 12 to 15, wherein the segmented payload lifting system includes a cantilever lifting system for lifting the first payload surface portion at one end of the first payload surface portion in a cantilever manner.

17. An object handling system as described in any one of claims 12 to 16, wherein the first effective load surface includes at least one first surface prong, and the at least one first surface prong is sized to fit between the peaks of the corrugated storage shelf of the object handling system, and wherein the second effective load surface includes at least one second surface prong, and the at least one second surface prong is sized to fit between the peaks of the corrugated storage shelf of the object handling system.

18. The object handling system of claim 17, wherein the first payload surface and the second payload surface each include a plurality of tines sized to fit between the peaks of the corrugated storage shelf of the object handling system.

19. An object handling system as claimed in any one of claims 12 to 18, wherein the payload translation system includes a bi-directional roller system for extending the payload out of the mobile chassis unit in each of two mutually opposite directions.

20. The object handling system of claim 19, wherein the bi-directional roller system comprises a slidable drive roller.

21. The object handling system of any one of claims 12 to 20, wherein the object handling system comprises a plurality of storage shelves and a plurality of automatically moving shuttles that move between the plurality of storage shelves.

22. A method of handling a payload of an autonomous mobile shuttle, the method comprising: providing a mobile chassis unit for moving the automated moving shuttle in at least one horizontal direction; supporting at least one object on a payload surface of a payload, the payload surface comprising at least one tine; moving the payload in a second horizontal direction such that the at least one tine moves between peaks of a corrugated storage shelf of the object handling system; as well as The first payload surface portion or the second payload surface portion is independently raised and lowered along a third vertical direction.

23. The method of claim 22, wherein the method further comprises rotating the payload about a first axis, the first axis being orthogonal relative to the one horizontal direction.

24. The method of any one of claims 22 to 23, wherein moving the payload in the second horizontal direction comprises engaging troughs of the corrugated storage shelf with guide rollers of the at least one tine, thereby distributing the load of the payload to the storage shelf.

25. The method of any one of claims 22 to 24, wherein independently raising and lowering the first payload surface portion or the second payload surface portion comprises rotating a cam-based lifting system for lifting the first payload surface portion at each of two opposing ends of the first payload surface portion.

26. The method of any one of claims 22 to 25, wherein independently raising and lowering the first payload surface portion or the second payload surface portion comprises lifting the first payload surface portion at one end of the first payload surface portion in a cantilevered manner.

27. A method as claimed in any one of claims 22 to 26, wherein the method further comprises providing a plurality of levels of storage shelves, and at least one automated mobile vehicle, the at least one automated mobile vehicle comprising a lifting system to enable the automated mobile vehicle to move vertically along a vertical structure.

28. A method as claimed in claim 27, wherein the self-propelled vehicle further comprises a vehicle base, the vehicle base comprising at least two wheels for moving the self-propelled vehicle in at least one direction, the at least one direction being substantially orthogonal to the vertical direction; a payload receiving portion for receiving at least one object thereon for movement by the self-propelled vehicle; and a support structure on the vehicle base for supporting the payload receiving portion, the support structure comprising a coupling system for coupling the support structure of the mobile vehicle to the vertical structure at least in part by moving the support structure away from the vehicle base.

29. The method of any one of claims 22 to 28, wherein the method further comprises changing the position of an object on the payload surface.

30. The method of claim 29, wherein changing the position of the object on the payload surface comprises moving the object away from a center of the payload surface.

31. The method of claim 30, wherein the method further comprises storing more than one object at a location on the storage shelf.

Images