System and method for providing movable shuttle load handling system with movable vehicle

Abstract

Disclosed is an object handling system (210) comprising: an automatically movable shuttle (218) comprising a movable chassis for moving the automatically movable shuttle in a first direction, a payload for supporting at least one object thereon, and a payload translation system, the payload comprising a plurality of prongs; and an automatically movable vehicle (212) movable in a second direction substantially orthogonal to the first direction, the automatically movable vehicle comprising a receiving surface (236) for receiving the plurality of prongs of the payload, wherein the payload translation system of the automatically movable shuttle is for translating the payload towards the receiving surface of the automatically movable vehicle, and the payload translation system causes the plurality of prongs to be adapted to engage recessed areas within the receiving surface of the automatically movable vehicle.

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 (SKUs) and shipping objects, bins and boxes containing these articles, products, packages and SKUs. The present invention particularly relates to ASRS systems that require both long-term storage and medium-term storage (low throughput storage ratio) and short-term storage (high throughput storage ratio) such as where the storage is turned over every day. Long-term storage systems 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] Some existing ASRS and other handling systems are limited by the payload they can reliably deposit and pick up. Reliability is a core requirement because it is often the case that failures require human intervention within the system and human intervention has conflicting priorities in terms of 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 causes ripple effects throughout the rest of the system efficiency. The storage and access system is often the primary source of buffering and other system buffers are kept short.

[0005] Shuttle and lift systems, stacker systems, and tower robot systems, for example, are becoming increasingly common and have many benefits over more traditional crane-based systems in terms of system-level throughput and their tolerance to single-point failures without limiting the bulk of the system. Some of these systems work well with conventional bin (or pallet) based storage, which allows the payload interface to be a consistent design feature in the payload acquisition and storage bins. Payload transport in these systems ranges from controlled lift types with paired bottom locating features to engaged traction types that can be pulled from greater distances using side engagement bags (arguably the most common), which is traction using pulling fingers that reach behind.

[0006] Some of these systems involve reaching behind objects and suggest compatibility with conventional 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 present the box in a bin or shipment. Additionally, these existing systems have difficulty handling unboxed loose items that might otherwise be transported, such as shrink-wrapped beverage boxes, dog food bags, cat litter, etc., all of which exhibit widely varying sizes, shapes, and material properties.

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

[0008] According to one aspect, the present invention provides an object handling system, comprising: an automated movable shuttle comprising a movable chassis for moving the automated movable shuttle in a first direction, a payload for supporting at least one object thereon, and a payload translation system, the payload comprising a plurality of tines; and an automated movable carrier movable in a second direction substantially orthogonal to the first direction, the automated movable carrier comprising a receiving surface for receiving the plurality of tines of the payload, wherein the payload translation system of the automated movable shuttle is used to translate the payload toward the receiving surface of the automated movable carrier, and the payload translation system adapts the plurality of tines to engage a recessed area within the receiving surface of the automated movable carrier.

[0009] According to another aspect, the present invention provides an object handling system, comprising: an automated movable carrier that is movable in a substantially vertical direction, the automated movable carrier comprising a receiving surface for receiving at least one object; and an automated movable shuttle that comprises a movable chassis for moving the automated movable shuttle in a substantially horizontal direction and a payload for supporting at least one object thereon, wherein the automated movable shuttle further comprises a payload transfer system for transferring at least one object between the receiving surface of the automated movable carrier and the payload of the automated movable shuttle.

[0010] According to another aspect, the present invention provides a method for processing an object, comprising: moving an automatic movable shuttle in a substantially horizontal direction including at least one exchange area; moving an automatic movable carrier in a substantially vertical direction including at least one exchange area; and exchanging at least one object between the automatic movable shuttle and the automatic movable carrier at at least one exchange area. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0012] Figure 1 A schematic diagram of an object handling system according to an aspect of the present invention is shown, the object handling system comprising a plurality of movable shuttle units, each movable shuttle unit being associated with a level of a shelving system;

[0013] Figure 2 Shows Figure 1 An illustrative schematic side view of a movable shuttle unit;

[0014] Figure 3 Shows Figure 2 illustrative schematic end view of a movable shuttle unit;

[0015] Figure 4 Shows Figure 2 An illustrative schematic exploded view of a movable shuttle unit;

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

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

[0018] Figure 7 Shows Figure 6 An illustrative schematic front view of a movable shuttle unit of the invention with the payload rotated 90 degrees;

[0019] Figure 8 Shows Figure 6 An illustrative schematic front view of a movable shuttle unit of the invention with the payload rotated 180 degrees;

[0020] Fig.9A and Fig. 9B Shows Figure 2 An illustrative schematic enlarged view of a movable shuttle unit of FIG. 1 with the fork tines lowered ( Fig. 9A ) and where the tines are raised ( Fig. 9B );

[0021] Fig.10 Shows Figure 8 An illustrative schematic diagram of a movable shuttle unit of the invention with a payload extending above a shelf;

[0022] Fig.11 An illustrative schematic diagram of a cam lift system for use in a movable shuttle unit is shown, showing the cam pushing downward on a rocker to lift the tines upward;

[0023] Fig.12 Shows Fig.11 An illustrative schematic diagram of a cam lift system of , wherein rotation of the cam causes the rocker to raise, thereby allowing the fork tines to rest in a lowered position;

[0024] Fig.13 Shows Fig.11 An illustrative schematic diagram of a cam lifting system of FIG. 1 , wherein one cam pushes a first rocker downward, lifting a first set of tines upward, and showing another cam rotating so that another rocker is raised, thereby allowing a second set of tines to rest in a lowered position;

[0025] Fig.14 Shows Fig.13 An illustrative schematic side view of a movable shuttle unit of wherein one set of tines is raised and one set of tines is lowered;

[0026] Fig.15 shows an illustrative schematic exploded view of a payload portion of a movable shuttle unit including a suspended cam system according to another aspect of the present invention;

[0027] Fig.16 Shows Fig.15 an illustrative schematic diagram of a payload portion of with the tines in a lowered position;

[0028] Fig.17 Shows Fig.15 an illustrative schematic diagram of a payload portion of with the tines in a raised position;

[0029] Fig.18 Shows Fig.15 an illustrative schematic diagram 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 Shown adjacent to the shelving system Fig.17 An illustrative schematic diagram of a movable shuttle unit;

[0031] Fig. 20 Shows Fig.19 An illustrative schematic diagram of a movable shuttle unit of the shelving system wherein a payload is extended on a shelf of the shelving system;

[0032] Fig.21 shows an illustrative schematic diagram of a movable shuttle unit including bi-directionally extendable payload teeth according to another aspect of the present invention;

[0033] Fig. 22 Shows Fig.21 an illustrative schematic exploded view of a movable shuttle unit of with its movable bridge at a first end;

[0034] Fig.23 Shows Fig.21 an illustrative schematic exploded view of a movable shuttle unit of with its movable bridge at an opposite second end;

[0035] Figures 24A to 24D Shows Fig.21 An illustrative schematic diagram of a movable shuttle unit showing an unextended payload ( Fig.24A ), showing the effective load extending in the first direction ( Fig. 24B ), showing that the movable bridge has moved to Fig. 22 The opposite side shown in ( Fig.24C ), and shows a payload extending in an opposite second direction ( Fig.24D );

[0036] Fig.25A and Fig.25B Shows Fig.21 An illustrative schematic enlarged view of the tines of the payload of the movable shuttle unit of FIG. 1 , showing the tines of the payload before transfer ( Fig.25A ) and after transfer (where the roller contacts the lower surface within the rack system) ( Fig.25B ) rollers on the ends of the tines supported by a movable shuttle unit;

[0037] FIG. 26A to FIG. 26D An illustrative schematic diagram of a mobile shuttle unit including a payload position adjustment system according to further aspects of the present invention is shown, showing an object ( 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 showing the transfer of an additional object to a second position on the shelving system in front of the first position ( Fig.26D );

[0038] Fig. 27 Shows Fig.21 An illustrative schematic bottom view of a translation system of a movable shuttle unit;

[0039] Fig.28 Shows Fig. 27 An illustrative schematic bottom view of the translation system of , wherein the bridge has begun to move to the opposite end of the movable shuttle unit;

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

[0041] Fig.30 Shows Fig.29 An illustrative schematic 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 schematic side view of a translation system of , wherein the bridge has been moved to the opposite sending end;

[0043] Fig.32 Shows Fig.29 illustrative schematic 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 schematic front end view of a system of showing a lift platform for vertically moving an object;

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

[0046] Fig.35 shows an illustrative schematic side view of a system including an autonomous movable vehicle according to another aspect of the present invention;

[0047] Fig.36 Shows a nearly vertical structure Fig.35 An illustrative schematic enlarged side view of an automated movable vehicle;

[0048] Fig.37 Shows the vertical structure Fig.36 An illustrative schematic diagram of an automated movable vehicle;

[0049] Fig.38A and Fig.38B Shows Fig.37 An illustrative schematic exploded view of an automated movable vehicle of FIG. 1 , showing an exploded side view ( Fig.38A ) and exploded end view ( Fig.38B );

[0050] Fig.39A and Fig.39B Shows Fig.37 illustrative schematic side view of an automated movable carrier of FIG. 1 , showing the automated movable carrier in a central position for vertical engagement ( Fig.39A ) and vertical joint vertical structure ( Fig.39B );

[0051] Fig.40 Shown has been raised to an elevated position in a vertical structure Fig.37 An illustrative schematic exploded view of an automated movable vehicle;

[0052] FIG. 41A to FIG. 41C Shows Fig.40 illustrative schematic enlarged view of an automated movable carrier of FIG. 1, showing a mobile shuttle unit approaching the automated movable carrier ( Fig.41A ), showing that the mobile shuttle unit has engaged an object on the automated movable carrier ( Fig.41B ), and shows that the mobile shuttle unit has pulled the object from the automated movable carrier onto the mobile shuttle unit ( Fig.41C );

[0053] Fig.42A and Fig.42B Shows Fig.40 An illustrative schematic enlarged view of a portion of an automated movable vehicle of FIG. 1 showing a support structure ( FIG. 2 ) lowered relative to a base of the automated movable vehicle. Fig.42A ), and a support structure shown raised relative to the base ( Fig.42B );

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

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

[0056] Fig.45 shows an illustrative schematic side view of an object handling system including a plurality of vertical structures that may be used to store objects according to further aspects of the present invention;

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

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

[0059] Fig.48Shows Fig.45 illustrative schematic enlarged side view of a portion of an object handling system of;

[0060] Fig.49 An illustrative schematic diagram showing an object handling system including a plurality of handling conveyors for feeding objects in place of a lift system at a shelving system according to another aspect of the present invention;

[0061] Fig.50 Shows the engagement Fig.49 an illustrative schematic enlarged view of a portion of a movable shuttle unit payload of a portion of a plurality of processing conveyors;

[0062] Fig.51 Shows the engagement Fig.49 A portion of a plurality of processing conveyors Fig.15 an illustrative schematic enlarged view of a portion of a payload of a movable shuttle unit; and

[0063] Fig.52 An illustrative schematic diagram of an object handling system including multiple handling conveyors in place of a lift system at a shelf system for making objects available to any one of a plurality of feed movable shuttle units according to another aspect of the invention is shown.

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

[0065] The present invention provides an automated movable shuttle for use in an ASRS or other object handling system. According to one aspect, the automated movable shuttle includes, for example: a movable base unit for moving the automated movable 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 orthogonal to at least one direction of the payload of the automated movable shuttle; a payload translation system for translating the payload in at least a second direction 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 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. The degrees of freedom between the main axes of motion create flexibility in providing longitudinal heterogeneous storage, as discussed herein.

[0066] The payload handling techniques disclosed herein can be used with automated movable vehicles that move around a work environment using a variety of methods that balance speed, accuracy, cost, complexity, etc., including, for example, track-based systems, racks and pinions, belts and pulleys, cable pulling, or any number of other methods.

[0067] Mobile shuttle position feedback (sometimes called localization) can be achieved by many means familiar to those skilled in the art of mobile robotics, including but not limited to odometer measurements, integrated calculations using inertial feedback from a measurement unit (IMU), unique positioning markers (sometimes called fiducials), non-unique positioning markers with regional 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 should also be understood that even with a movable shuttle engaging a rack system, the shuttle (including in some cases a shuttle-lift-transport) can also leave the rack altogether to perform a package exchange or other operation outside the rack. Additionally, the choice of drive should be paired with the choice of positioning technology and the additional mobility outside of the capture track embodiment mentioned above to achieve the overall system goals.

[0069] According to various aspects, the system provides versatility in payload handling using multiple closely spaced tines with the ability to advantageously dock with almost any package that is twice as wide as the tine spacing. Moreover, the design can be scaled up or down to accommodate different environments. For example, the tines can be spaced closer together to handle even small objects, or spaced much farther apart for consistent large objects. According to one aspect, the smallest object can be at least 3 inches or 5 inches in the shortest dimension. Utilizing this aspect, smaller objects are transportable when grouped into larger carrying units (e.g., in boxes, bins, pallets, or shipments).

[0070] According to a further aspect, the present invention provides a mobile unit payload comprising roller tips that share the load between rollers resting on the shelf trough and guides or rollers within the shuttle body during extraction after lifting. The same load sharing occurs during shelf insertion and exchange with system level introduction and unloading devices. This strategy of providing support from both ends is very important in terms of component selection for a given load.

[0071] Figure 1A system 10 is shown that includes a plurality of shelves 12 arranged in two arrays opposing each other with a plurality of movable shuttle units 14 therebetween. Each movable shuttle unit can receive objects at a processing end 16 of the system, move along a row between a plurality of shelf positions, and deliver objects to any of the shelves on either side of the row. The movable 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 deliver the retrieved objects via an elevator platform 18 that is located at each of the rows (see below). Fig.35 The operation of the system (and all systems disclosed herein) can be provided by one or more computer processing systems 100, 200 in communication with the movable shuttle unit and conveyor system described herein. The position of the movable shuttle unit along the shelf can be determined by any of wheel rotation monitoring, shelf markings, global positioning system, or remote (wireless) signal detection (such as vision, infrared, echolocation, etc.).

[0072] refer to Figure 2 and Figure 3 Each movable shuttle unit 14 (according to one aspect of the present invention) includes a movable unit chassis 40 having a track 44 ( Figures 5 to 10 1 and 2 ) and four wheels 42 of the mobile unit 14 (eg, two of the four wheels are powered by a motor 41 within the chassis housing). 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 , a payload 50 including tines 26 is disposed on a translation system 52 for moving the payload relative to a translation base 54. In particular, 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 movable unit chassis 40 via a gear 56 and a rotation system 58. The base 54 includes an attachment gear 56 that is driven relative to the chassis 40 by the rotation system 58. The tines 26 are provided in two sets, each of which is 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 the positioning of the shuttle tines 26 so that they are longitudinally aligned with the troughs in the shelves 12 of the shelf system. According to other aspects, the system can separate the areas (aisles, vertical levels, longitudinal compartments) of the shelf by package size and the position varies less in the longitudinal direction. In these cases, the tines must still be aligned, but the one-to-one relationship of the tines to the troughs is not important, for example, a subset of the shuttles in the fleet may only see large packages, and may have a wider tine spacing of the payload and dock with 5 times the shelf spacing.

[0074] Figure 5 The tines 26 are shown in a lowered position, Figure 6 The fork 26 is shown raised, and both figures show the carrier 14 positioned between the shelves 12. In the lowered position, the fork 26 is at an altitude below the peak height of the adjacent shelf 12, and in the raised position, the fork 25 is above the peak height of the adjacent shelf 12. The shelves can be provided in a generally corrugated form, thereby providing alternating peaks and troughs. The translation system 52 can be engaged to extend the payload into the corrugated shelf 12 (either above the shelf or staggered between the peaks) to place objects on the shelf 12 or retrieve objects from the shelf 12. Figure 7 The payload is shown being rotated 90 degrees by the rotation system 58 (e.g., for loading or distribution, as described below with reference to Figure 33 to Figure 36 discussed above), and Figure 8 A 180 degree rotation is shown such that the tines 26 now face the payload of the opposing rack 12 .

[0075] Fig. 9A and Fig. 9B The tines 26 are shown each supported by a runner 27, and the runners each include one or more guide rollers 29. The corrugated shelf includes peaks 13 and troughs 11, and the runners 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 at a height below the top of the shelf surface, and Fig. 9B The tines 26 are shown in a raised position at a height above the top of the shelf surface. The corrugated shelf may be continuous (as shown) or discontinuous (eg formed by discontinuous u-shaped grooves) along the shelf direction. Fig.10 The payload is shown having been extended into the shelf 12 by the translation system 52. When objects are being placed on the shelf, the payload can be extended in a raised position (e.g. Fig.10 As shown in the figure (and then lowered when retracted), or the payload can be extended in the lowered position (and then raised when retracted) when removing objects from the shelf.

[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 cam (66) of the pair of cams being urged against a first cam follower 70 of a first rocker base 72, and the other cam of the pair of cams being urged against a second cam follower 74 of a second rocker base 76. When a rocker base is depressed, an associated set of tines is raised. Fig.11 It is shown that the two cams 66, 68 have been rotated so that the two rockers 72, 74 are pushed downwards, thereby raising all the tines. Fig.12 It is shown that both cams 66, 68 have been rotated further so that neither rocker 72, 74 is engaged by the cams, thereby causing all tines to be lowered. Fig.13 One cam 68 is shown having been rotated so that the rocker 74 is pushed downward, thereby raising the associated tine (e.g., Fig.14 80 shown), 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., as Fig.14 82) shown is not raised.

[0077] Therefore, according to Figures 1 to 14 In a system where each movable shuttle unit provides rotational adjustment of its payload, segmented height adjustment of its payload, and translational adjustment of its payload. Because the system records the location where objects are placed, the system has a record of the positions of all objects on the shelf at all times. For example, a payload lift system can be used with a multi-position cam to provide segmented lifting of the payload teeth. This allows for greater flexibility in handling and placing objects of varying sizes onto the shelf, freeing the system from using overly large designated discrete storage locations. As a result, smaller objects can be stored more closely together. This concept may be referred to as longitudinal heterogeneous storage.

[0078] According to further aspects, the system of the present invention may include multiple sets of tines mounted in a cantilevered manner on an elevator base, the elevator base being a movable translation system. Fig.15 A movable shuttle unit 14' ( 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 movable unit chassis 40', as described above with reference to Figures 1 to 14 As discussed. Fig.15As 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 moved by a rotation system 58 (a portion of which is located at Fig.19 and Fig. 20 100 and 101 , respectively. The mobile unit chassis 40' is shown in the figure. The 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 are rotated so that the cam followers 118, 120 are pushed upward, the suspension seats 104, 106 are also pushed upward, thereby bringing the fork 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 tines (shown at 122) is raised while the other set of tines (shown at 124) is 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, freeing the system from using overly large designated discrete storage locations and allowing smaller objects to be stored more closely together.

[0080] Fig.19 A movable shuttle unit 14' is shown adjacent to the shelf 12. For clarity, only one shelf is shown; the unit 14' can be used between rows of shelves, which are described above with reference to Figures 2 to 14 As discussed, it is set up in multiple levels. Fig. 20 The tines 102 on seats 104, 106 are shown advancing on the shelf 12. Because 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, because the system records the location of where objects are placed, the system has a record of the location of all objects on the shelf at all times. Again, the entire operation can be controlled by one or more computer processing systems 100.

[0081] According to further aspects, 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 racks, rather than rotating the payload. Fig.21 A movable shuttle unit 14 is shown including a movable unit chassis 40" with wheels 42 as discussed above. The movable shuttle unit 40" includes a fork tine 130 mounted on a height adjustable slide 132. As described below with reference to Figures 31 to 34 As discussed, each of the tines 13 can be raised and lowered relative to their respective slides 132. The slides 132 are supported by and travel with a bridge 134 (having slidable drive rollers) that is movable between the ends of the movable chassis unit 40". Fig. 22 An exploded view of the upper portion of the movable chassis unit is shown with the bridge 134 at one end, and Fig.23 An exploded view of the movable chassis unit is shown in which the bridge 134 has been moved to the opposite end.

[0082] The slide 132 also rides on support rollers 136, 138 and is thereby supported as the slide extends out over the shelf until the roller ends engage the shelf troughs. The support rollers 136, 138 support the load while the bridge 134 drives the slide and tines outwardly. Fig.24A A bridge 134 is shown adjacent to the side of the movable shuttle unit 14", and Fig. 24B The tines 130 are shown extending over 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 movable shuttle unit 14". Fig.24D The tines 130 are shown extending over the second shelf 12 .

[0083] Similar to Fig. 9A and Fig. 9B The system shown in Fig.25A , Fig.25B The tines 130 are shown each supported by a slide 132, but the slide 132 is bi-directional with guide rollers 133 on each end thereof. Fig.25A Shown is the runner that will engage the lower portion of the shelf, Fig.25B The slide is shown having engaged the lower portion of the shelf, acting to displace some of the weight of any load on the slide from the carrier 14 to the shelf. The slide 132 aligns with and enters the valleys 11 of the corrugated shelf, causing the guide rollers 133 to enter the valleys 11 of the shelf and begin distributing the load to the shelf during transfer. Fig. 24B and Fig.24DThe payload is shown having been extended into the shelf 12 by the translation system 136. The payload may be extended in a raised position (and then lowered when retracted) when objects are being placed on the shelf, or may be extended in a lowered position (and then raised when retracted) when objects are being removed from the shelf.

[0084] The automated shuttle vehicle 14 may also include a payload position adjustment system for adjusting the position of an object on the payload receiving portion of the vehicle. For example, 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 can be moved by a power system 156 via a track 154 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 provide 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 toward 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 retracted, and then the support structure is lowered to prevent the push rod 152 from colliding with the shelf. According to further aspects, the payload position adjustment portion can accommodate changes in the height of the tines 130 relative to the shelf 12. Additional objects can then be loaded onto the automated movable carrier, and the objects are again moved to a forward position on the payload receiving surface. Reference Fig.26D , additional objects 162 may then be similarly placed on the shelf, but in a proximal position on the shelf. Fig.26A and Fig.26B In the embodiment of the present invention, the fork tines 130 are raised relative to the shelf. Fig.26C and Fig.26D In this way, multiple objects can be placed at a shelf position that otherwise might only receive one object.

[0085] Fig. 27 and Fig.28 The slideway 132 is shown riding over the non-actively driven pinion 138 (and thereby remaining aligned with one another) under the driving force from the bridge 134 to extend away from the movable chassis unit housing. Fig. 27 A bottom view showing the slide and pinion, and Fig.28The bridge is shown having been moved from the side of the carrier. Drive rod 137 engages rack pulley 139 on the underside of slideway 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 32 As shown. Each side of the unit 14" may include bi-directional tines for moving the tines in either of opposite directions (e.g., for accessing an opposing shelf 12, as discussed above), and this is achieved without rotating the payload.

[0086] Fig.29 The tine 130 is shown in a raised position because the cam 140 rotates against the cam blocks (these cam blocks also act as a linkage, such as using a four-bar linkage) so that the tine 130 is raised relative to the slide 132 when raised from either end, and Fig.30 The tines 130 are shown in a lowered position because the cam 140 is rotated so that the tines 130 are not raised relative to the slide 132. As discussed above, the cam 140 can be formed of different shapes, thereby allowing different groups of tines to be raised and lowered together or independently by providing cams of different shapes. Also as discussed above, the bridge 134 can then be translated to the opposite side of the movable shuttle unit (such as Fig.31 ), and then the cam 140 can be rotated again so that the fork 130 is raised relative to the slide 132 again (as shown in FIG. Fig.32 136). By moving the bridge 134 (with the drive rod 137) between the ends of the movable shuttle unit 14", the tines can be extended in either of two opposite directions to approach 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 rack gear 139 on the underside of the slide 132. When the tines are driven outwardly, the drive rod 137 is locked in rotation. According to further aspects, the drive rod can be used to maintain alignment of the slides, and the pinions 136, 138 can be used to move the payload in a translational manner.

[0087] refer to Fig.33 and Fig.34 , the system 10 can receive input objects and provide retrieved objects via an elevator platform 18 that moves between the processing ends of each of the rows. Fig.33 The lift platform 18 is shown having just been loaded (eg, by a programmable motion device or by a human operator), and Fig.34The elevator platform 18 is shown being raised to the destination level, where the shuttle unit 14 engages the object from the elevator platform. Likewise, the elevator platform and the shelf itself are formed of a corrugated platform, which allows the tines of the movable shuttle unit to enter the platform and then rise to engage the object. According to other aspects, the elevator platform can be provided by a roller conveyor section that includes rollers spaced apart to allow the tines to be positioned between (and on) the rollers, as described below with reference to Fig.45 As discussed above. While keeping the object lowered below the surface, delivering the object is performed in the reverse order of the tines. Operation of the system (and all systems disclosed herein) can be provided by one or more computer processing systems 100 in communication with the movable shuttle unit and conveyor system described herein.

[0088] According to other aspects and reference Fig.35 The present invention provides an object handling system 210, which includes a plurality of automated movable vehicles 212 that can move toward and upwardly along a vertical structure 214 for providing objects to or removing objects from a multi-level shelf 216 via a shuttle vehicle 218. The shuttle vehicles 218 are each disposed on a shelf level (e.g., 220, 222, 224) between a pair of opposing shelves on each level. The navigation of each automated movable vehicle 212 around an environment can be facilitated by unique markers 228, which each vehicle 212 uses (via a detection unit on its underside) to confirm the proper position and orientation of the vehicle, or to instruct the vehicle how to adjust its movement in another pass to align the vehicle with the marker 228. According to further aspects, navigation of the automated movable 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, echolocation, and global or local positioning systems. Each automated movable carrier 212 includes two independently operable drive wheels 230 that can move the carrier in a forward or rearward direction, as well as rotate the carrier by supplying more power to one drive wheel than the other drive wheel or by rotating each drive wheel in opposite directions to rotate the carrier in place. The casters 232 can be used to facilitate a hierarchical payload receiving portion 236 on which a bin holding an object or objects can be placed for movement. The payload receiving portion 236 can be formed by a plurality of spaced apart ribs and supported by a support structure 234. The support structure 234 is height-adjustably mounted on a carrier base 238 (as discussed in more detail below).

[0089] The object handling system may be used in, for example, an ASRS system or other object handling systems that require both long-term storage and medium-term storage (low throughput storage ratio) and short-term storage (high throughput storage ratio) where, for example, storage is turned over daily. Long-term storage systems and medium-term storage systems require access to a larger 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 is provided at each of the four corners of the vertical structure 214, and each gear rack 240 includes a lowermost end 242 that terminates well above the floor. The vertical structure 214 may (or may not) include support legs 244 and a vertical structure base plate 246. The automated movable vehicle 212 can be driven into the base of the vertical structure 214, and the lowermost ends 242 of the vertically extending lifting gear racks at least clear the outer portion of the automated movable vehicle 212. Fig.37 The automated movable carrier 214 is shown having entered the base of the vertical structure. The outermost portion (at its corner) of the automated movable carrier 212 is clear of the lowermost end 242 of the lifting gear rack 240. As described above, the vertical structure may omit the support legs extending upward from the floor and base plate, wherein the vertical structure includes support members that terminate well above the floor.

[0091] Further references Fig.38A and Fig.38B , the automated movable vehicle 212 includes a payload receiving portion 236 that includes support ribs 237 that rise from a floor and rear wall 235 that provide a floor area 239 . Fig.38A shows an exploded side view of the automated movable vehicle 212, and Fig.38B An exploded end view of the automated movable vehicle 212 is shown. The lifting pinion 250 extends beyond the periphery of the payload receiving portion 236. The support structure 34 includes a motor 270 with 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 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 a motor in the base 238 of the vehicle.

[0093] The automatically movable vehicle 212 can readjust its position within the base of the vertical structure 214 via actuation of either or both independently drivable bi-directional drive wheels 230. The vehicle 212 can be moved 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 manner, 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 with wheels 230, wheel motors 256 and casters 232. The carrier base 238 also includes a base top 262, which includes four base gear 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 belts 272. Further reference Fig.38B Each multipurpose drive shaft 274 includes two attached base pinions 250 (at its ends) and two attached lifting pinions 276. The base pinions 276 (when powered by the motor 70) cause the support structure 234 to climb up the base gear rack 264 of the carrier base 238, thereby vertically separating the support structure 234 from the carrier base 238.

[0095] In particular, 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 activated and climbs up the base gear rack 264, the support structure 234 is vertically separated from (lifted away from) the carrier base 236. The degree of separation is controlled by the capped slide bar 278, which maintains the 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 multipurpose drive shafts 274. In particular, 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 gear rack 264, thereby causing the lift pinion to contact the lift gear rack, and continued rotation subsequently causes the lift pinion 250 to climb up the lift gear rack 240, thereby causing the carrier 212 to rise along the vertical structure 214. Operating the motor 270 in an opposite second direction causes the lift pinion to lower the carrier 212 along the lift gear rack 240 of the vertical structure, and when the base pinion 276 contacts the base gear rack 264, the support structure 234 is again brought into contact with the carrier base 238. The capped slide bar 278 terminates the separation of the support structure 234 from the carrier base 238 , so 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] The base pinion 276 climbs up the base gear rack 264 when driven by the motor via the belt 272. 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 gear 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 as the lifting pinion 250 climbs up the lifting gear rack 240. As the lifting pinion 250 approaches the lifting gear rack 240, the tapered end of the sliding guide 252 facilitates the engagement of the pinion 250 with the rack 240, and the pinion 240 is maintained aligned at least in part by the sliding guide 252 and the freely rotating roller guide 254 as it travels along the rack 240.

[0098] Reference again Fig.35 Each level of shelves 220, 222, 224 includes a shuttle carrier 218 that moves objects to and from the automated movable carrier 212 and to and 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 movable carrier 212. For example, Fig.35 Shuttle carrier 218 is shown on level 220 facing the shelves in the foreground, shuttle carrier 218 is shown on level 222 facing the vertical structure 214, and shuttle carrier 218 is shown on level 224 facing the shelves far side (away from the foreground).

[0099] Each shuttle carrier can receive an object from a movable carrier 218, move along a row between a plurality of shelf positions, and provide the object to any of the shelves on either side along the row. The movable shuttle carrier 218 is also adapted to retrieve an object from a shelf and bring the retrieved object to the movable carrier 218. The system 210 can receive an input object and provide the retrieved object via the movable carrier 218 moving between the processing ends of each of the rows. The operation of the system (and all systems disclosed herein) can be provided by one or more computer processing systems 200 in communication with the movable carrier 218 and the automated movable carrier 212 described herein.

[0100] As discussed above, each movable shuttle carrier (according to one aspect of the invention) includes four wheels for moving the carrier along tracks mounted to the inside of the shelf (e.g., two of the four wheels are powered by motors within the chassis housing, as described above with reference to Figure 3 The movable unit chassis is a movable unit chassis (as discussed above). The position of each movable 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 attached gears driven by the rotation system relative to the chassis. The tines are provided in two sets, each of which is mounted for lifting and lowering movement by an independent lift actuation system.

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

[0102] As described above, rotation of the shaft 274 causes the movable carrier 212 to move upward and downward along the lifting gear rack 240 when driven by the lifting gear 276. Fig.40 The movable carrier 218 is shown having been raised along the lifting gear rack 240, thereby 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 movable carrier 212. The tines 326 can be lowered so that when the shuttle carrier 218 approaches the movable carrier 212, the tines 326 pass between the support ribs 237 of the payload receiving portion 236.

[0103] Fig.41A The tines 326 are shown in a lowered position, and Fig.41B The tines 326 are shown as having been raised, thereby shifting the load of the object 280 onto the tines 326. Placing the object onto the movable carrier involves the reverse process (raising the tines, moving between the support ribs, and lowering the tines). Fig.41C It is shown that the object 280 has been transferred to the movable carrier 2318 for delivery to a storage location between multiple shelves 12. In the lowered position, the fork 326 is at an altitude below the peak height of the adjacent shelf 312 and the support ribs 237 of any adjacent movable carrier 212. In the raised position, the fork 326 is above the peak height of the adjacent shelf 312 and the support ribs 237 of any adjacent movable carrier 212. The shelf can be provided in a generally corrugated form, thereby providing alternating peaks and troughs. The translation system 352 can be engaged to extend the payload into the corrugated shelf 312 (or above the shelf or staggered between the peaks) to place the object on the shelf 312 or retrieve the object 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 movable carrier 218) via the rotation system 358 (eg, for loading or dispensing relative to the shelf 312).

[0104] The forks 326 are each supported by a slideway, and each slideway includes one or more guide rollers. The corrugated shelf includes crests 13 and troughs 11 ( Fig. 9B ), and the slide is aligned with and enters the trough 11, so that the guide roller enters the trough 11 of the shelf and begins to distribute the load to the shelf during transfer. The corrugated shelf can be continuous (as shown) or discontinuous along the shelf direction (for example, formed by discontinuous U-shaped grooves). The payload receiving forks 326 extend into the shelf 312 through the translation system discussed above. When an object is being placed on the shelf, the payload receiving forks 326 can be extended in a raised position (and then lowered when retracted), or when an object is removed from the shelf, the payload can be extended in a lowered position (and then raised when retracted).

[0105] The tine lift actuation system is 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 can be urged against a first cam follower of a first rocker base, and the other of which can be urged against a second cam follower of a 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 depressed, the associated set of tines is raised.

[0106] Thus, each movable shuttle unit provides rotational adjustment of its payload, height adjustment of its payload, and translational adjustment of its payload. Because the system records the location where the objects are placed, the system has a record of the positions of all objects on the shelf at all times. For example, a payload lift system can be used with a multi-position cam to provide segmented lifting of the payload teeth. This allows for greater flexibility in handling and placing objects of different sizes on the shelf, freeing the system from using overly large designated discrete storage locations. Thus, smaller objects can be stored closer together. This concept can be referred to as longitudinal heterogeneous storage.

[0107] same, Fig.40 The movable carrier 212 is shown being lifted as the shuttle carrier 218 approaches the loading area, and Fig.41A The movable carrier 312 and shuttle carrier 18 are shown at 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 fork tines 326 are raised (via rotation of the cams 366, 368), the object 280 is lifted and supported by the fork tines 326 instead. Fig.41C As shown, the tines 326 are pulled back toward the inside of the shuttle carrier 218 while the payload object 280 is carried by these tines. When the shuttle carrier 218 moves to the specified destination shelf position along the track 344, the tines 326 can then be lowered or (preferably) maintained in the raised position. Then, the rotation system 352 is engaged to rotate the payload, thereby aligning the free ends of the teeth 326 toward the destination position shelf (the destination position shelf is any side shelf in the opposite side shelf 312). The shuttle carrier 218 rotates toward the first side shelf 312 for moving the object 80 to the right side (as shown) shelf. The shuttle carrier 218 turns toward the left side (as shown) shelf 312, and has moved the raised tines into the left side shelf for moving the object 280 to the second opposite side shelf.

[0108] Fig.42A , Fig.42BAn autonomous movable vehicle 410 according to another aspect of the 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 while being optionally (at least partially) guided by a capped slide 416. Once raised, a lifting pinion 420 engages a lifting rack gear of the vertical structure and moves along the vertical structure while being guided by the slide rails 122 and roller guides 124 as discussed above. The vehicle 410 also includes a screw drive system 430 (e.g., four screw drives or ball screw systems). Each screw drive system 430 includes a screw 432 and an assembled 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. When the support structure 412 is raised, the lifting pinion 420 engages the lifting rack gear of the vertical structure and moves along the vertical structure while being guided by the slide rails 422 and roller guides 424 as discussed above. Further, 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 As discussed.

[0109] Fig.43A , Fig.43B An automated movable vehicle 440 is shown in accordance with another aspect of the invention that similarly includes a support structure 412 having a payload receiving portion 414 that can be raised and lowered relative to a vehicle base 418 while optionally (at least partially) being guided by a capped slide bar 416. Once raised, a lift pinion 420 engages a lift rack gear of the vertical structure and moves along the vertical structure while being guided by the slide rails 122 and roller guides 124 as discussed above. The vehicle 440 also includes a linear drive system 442 (e.g., four linear drive systems). Each linear drive system 442 includes a linear drive rod 446 ( Fig.43B43 (shown in FIG. 4 ), the distal end 444 of the linear drive rod is fixed to the support structure base plate 436, and the proximal end is 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 carrier 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. When the support structure 412 is raised, the lifting pinion 420 engages the lifting rack gear of the vertical structure and moves along the vertical structure while being guided by the slide rails 422 and roller guides 424 as discussed above. Further, 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 As discussed.

[0110] Fig.44A , Fig.44B An automated movable carrier 470 according to another aspect of the 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 when optionally (at least partially) guided by a capped slide 416. Portions of the side walls of the carrier base are removed to illustrate the lifting system discussed below. Once raised, the lifting pinion 420 engages the lifting rack gear of the vertical structure and moves along the vertical structure when guided by the slide rails 122 and roller guides 124 as discussed above. The carrier 470 also includes cams 474 that are pushed against followers attached to rockers 476. The cams 474 are rotated by a drive system 478. The ends of the rockers 476 are attached to beams 480 that support sub-support structures 482, which in turn support the support structure 412. Fig.44A Cam 474 is shown selected 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 rotated 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. Again, when the support structure 412 is raised, the lifting pinion 420 engages the lifting rack gear of the vertical structure and moves along the vertical structure while being guided by the slide rails 422 and roller guides 424 as discussed above. Further, 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 herein. According to one aspect, the automated movable shuttle includes, for example: a movable base unit for moving the automated movable 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 orthogonal to at least one direction of movement of the automated movable shuttle; a payload translation system for translating the payload in at least a second direction orthogonal to the first axis; and a payload lifting system for raising and lowering the payload surface receiving portion along a third direction parallel to the first axis. Thus, according to one aspect, the system provides four principal axes of motion, including driven movement of the carrier, rotation of the payload, extension of the payload, and lifting of the payload. The degrees of freedom between the principal axes of motion create flexibility in providing longitudinal heterogeneous storage, as discussed herein.

[0111] Mobile shuttle position feedback (sometimes called localization) can be achieved by many means familiar to those skilled in the art of mobile robotics, including but not limited to odometer measurements, integrated calculations using inertial feedback from a measurement unit (IMU), unique positioning markers (sometimes called fiducials), non-unique positioning markers with regional 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 should also be understood that even with a movable shuttle engaging a rack system, the shuttle (including in some cases a shuttle-lift-transport) can also leave the rack altogether to perform a package exchange or other operation outside the rack. Additionally, the choice of drive should be paired with the choice of positioning technology and the additional mobility outside of the capture track embodiment mentioned above to achieve the overall system goals.

[0113] According to various aspects, the system provides versatility in payload handling using multiple closely spaced tines with the ability to advantageously dock with almost any package that is twice as wide as the tine spacing. Moreover, the design can be scaled up or down to accommodate different environments. For example, the tines can be spaced closer together to handle even small objects, or spaced much farther apart for consistent large objects. According to one aspect, the smallest object can be at least 3 inches or 5 inches in the shortest dimension. Utilizing this aspect, smaller objects are transportable when grouped into larger carrying units (e.g., in boxes, bins, pallets, or shipments).

[0114] According to a further aspect, the present invention provides a shuttle carrier payload portion comprising roller tips that share the load between rollers resting on the shelf troughs and guides or rollers within the shuttle body during extraction after lifting. The same load sharing occurs during shelf insertion and exchange with system level introduction and unloading devices. This strategy of providing support from both ends is very important in terms of 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 further aspects, these groups of shelves may include vertical lift structures with other arrangements of shelves or groups of shelves. For example, Fig.45 An object handling system 500 is shown including a set 510 of mutually facing shelves 512, 514. The system 500 includes a first vertical lift structure 516 as discussed 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 movable carrier as discussed above with reference to the vertical lift structures 14, 314. Fig.46 shows a top view of system 500, and Fig.47 An end view of the system 500 is shown. The use of multiple vertical lift structures can increase the throughput of objects to and from the shelves 512, 514. Additionally, and as Fig.48 As shown, when the autonomous movable carrier is positioned within the vertical lift structure, the carrier itself can function 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 shelf level 546 of shelf 512. The payload receiving portions 540, 542, 544 can function as shelves (in this manner with automated shuttle carriers 18 ( Fig.46) exchange objects until they are needed for transportation).

[0116] Fig.49 A system 20 is shown that can receive input objects and provide retrieved objects via any one of a plurality of processing conveyors 22, each of which is associated with a level in a plurality of levels of a shelf row. Fig.50 , which shows an enlarged portion of the interchange between the movable shuttle unit 14 and the processing conveyor 22, the tines being sized to also fit between adjacent rollers 24 of the processing conveyor 22. Similar to the interchange between the movable shuttle unit 14 and the shelf 12, the movable shuttle unit 14, 14' can retrieve objects from the processing conveyor 22 and place the objects onto the processing conveyor 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 shown using a plate 25 that forms a surface (eg, a valley) beneath the roller 24 against which the guide roller engages. Fig.51 Shuttle unit 14' is shown positioning tines 102 between rollers to effect transfer to and from conveyor 22. However, it will be appreciated that providing a fixed valley (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 movable shuttle unit 14 is capable of receiving objects from and providing objects to a shelf via a processing end that includes a plurality of processing conveyors 32 that are each aligned with a shelf 12 and include movable units 15. Each movable unit 15 is identical to the movable shuttle unit 14, except that the units 15 are maintained at an exchange area and simply move objects 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 movable shuttle unit 15 to fit below the top surface so that objects can be moved to and from the processing conveyors by the movable shuttle unit, as described above with reference to FIG. Fig.50 and 51 As discussed, however, a movable shuttle unit is not required to rotate the payload.

[0118] For example, the object may travel in a lateral direction relative to the shelf 12 or may travel in a direction generally parallel to the shelf 12 (e.g., Fig.52 The objects may be received by any one of the processing conveyors 22 of each level (shown), where the objects may be provided from storage along each pair of processing conveyors 32 at each level. According to a further aspect, a conveyor elevator may be used just outside the unloading area to aggregate the various levels into a single entry / exit unloading area.

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

Claims

1. An object processing system, comprising: an autonomous movable shuttle comprising a movable chassis for moving the autonomous movable shuttle in a first direction, a payload for supporting at least one object thereon, and a payload translation system, the payload comprising a plurality of tines; and an autonomous movable vehicle movable in a second direction generally orthogonal to the first direction, the autonomous movable vehicle comprising a receiving surface for receiving the plurality of tines of the payload; The payload translation system of the automated movable shuttle is used to translate the payload toward the receiving surface of the automated movable vehicle, and the payload translation system adapts the plurality of tines to engage a recessed area within the receiving surface of the automated movable vehicle.

2. An object handling system as described in claim 1, wherein the receiving surface includes support ribs and a floor area, and the floor area is the recessed area that engages the fork tines of the automatically movable shuttle.

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

4. An object handling system as described in any one of claims 1 to 3, wherein the automated movable shuttle further includes a payload lifting system for raising and lowering the fork tines relative to a chassis of the automated movable shuttle.

5. The object handling system of claim 4, wherein the payload lifting system comprises a cam driven lifting system for lifting at least one end of the payload.

6. An object handling system as described in claim 4, wherein the payload lifting system includes a two-part cam-driven lifting system for independently lifting a first portion of the payload or the first portion of the payload and a second portion of the payload.

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

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 described in any one of claims 1 to 8, wherein the payload translation system includes a bi-directional roller system for extending the payload beyond the automatically movable shuttle in each of two opposite directions.

10. An object handling system as claimed in any one of claims 1 to 9, wherein the first direction is generally horizontal and the second direction is generally vertical.

11. An object handling system as described in any one of claims 1 to 10, wherein the object handling system includes a plurality of storage shelves and the automated movable shuttle reciprocates between the plurality of storage shelves.

12. An object processing system, comprising: an autonomous movable vehicle capable of moving in a generally vertical direction, the autonomous movable vehicle including a receiving surface for receiving at least one object; as well as An automated movable shuttle comprising a movable chassis for moving the automated movable shuttle in a generally horizontal direction and a payload for supporting at least one object thereon, wherein the automated movable shuttle further comprises a payload transfer system for transferring the at least one object between the receiving surface of the automated movable carrier and the payload of the automated movable shuttle.

13. The object handling system of claim 12, wherein the receiving surface includes support ribs and a floor area, and the floor area engages the tines of the payload of the automated movable shuttle.

14. The object handling system of claim 13, wherein each tine includes a guide roller for contacting a floor area of ​​the receiving surface.

15. The object handling system of any one of claims 12 to 14, wherein the automated movable shuttle further comprises a payload rotation system for rotating the payload relative to a chassis of the automated movable shuttle.

16. The object handling system of any one of claims 12 to 15, wherein the payload transfer system further comprises a payload lifting system for raising and lowering the payload relative to the chassis of the autonomous movable shuttle.

17. An object handling system as claimed in any one of claims 12 to 16, wherein the payload transfer system includes a bi-directional roller system for extending the payload beyond the automatically movable shuttle in each of two opposite directions.

18. An object handling system as described in any one of claims 12 to 17, wherein the object handling system includes a plurality of storage racks and the automated movable shuttle reciprocates between the plurality of storage racks.

19. A method of processing an object, comprising: moving an automated movable shuttle in a generally horizontal direction including at least one exchange area; moving the automated movable vehicle in a generally vertical direction including the at least one exchange area; as well as At least one object is exchanged between the autonomously movable shuttle and the autonomously movable carrier at the at least one exchange area.

20. The method of claim 19, wherein exchanging the at least one object between the autonomously movable shuttles and the autonomously movable carriers comprises adjusting a plurality of the autonomously movable shuttles in a lifting manner.

21. The method of any one of claims 19 to 20, wherein exchanging the at least one object between the autonomously movable shuttle and the autonomously movable carrier comprises adjusting a plurality of the autonomously movable shuttles in a translational manner.

22. The method of any one of claims 19 to 21, wherein the method further comprises rotating a payload of the autonomous movable shuttle.

23. The method of claim 22, wherein the method further comprises changing the position of an object on a payload surface of the autonomous movable shuttle.

24. The method of claim 23, wherein changing the position of the object on the payload surface comprises moving the object in a direction away from a center of the payload surface.

25. The method of claim 24, further comprising placing more than one object at the location of the storage shelf.

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