Material handling device with input / output station and method of use thereof

Abstract

A transfer station for a material handling system is provided. The system may include a plurality of carriers for retrieving items from a plurality of storage locations located in one or more shelves. The transfer station is configured to receive a vehicle such that the vehicle is driven into the transfer station and travels upward along a track in the transfer station. The transfer mechanism on the carrier cooperates with the transfer mechanism on the transfer station to transfer the articles from the carrier to the conveyor.

Description

[0001] Related Applications This application claims priority to U.S. Provisional Patent Application No. 63 / 410,211, filed on September 26, 2022. The entire disclosure of the above application is hereby incorporated herein by reference. Technical Field

[0002] The present invention relates to a material handling system for storing or retrieving articles. More specifically, the present invention relates to a material handling system comprising a plurality of destination areas and a plurality of carriers for carrying articles to and / or from the destination areas and for carrying articles to and / or from one or more workstations. Background Art

[0003] Storing and retrieving items to fulfill customer orders is laborious and time consuming, especially in systems where thousands of items are stored. Storing and retrieving items from thousands of storage areas requires a large amount of manpower to manually perform the process. Automated picking has been developed in many areas to reduce labor costs and improve customer service by reducing the time required to fulfill customer orders. However, known automated material handling systems are either very expensive or have limitations that hinder their effectiveness. Therefore, there is a need for automated storage and / or retrieval of items in various material handling applications. Summary of the invention

[0004] The present invention provides many inventive aspects related to material handling and / or storage and retrieval processes.

[0005] According to one aspect, a material handling system is provided that includes a storage assembly that houses a plurality of containers, a plurality of delivery vehicles, a transfer station, and a first conveyor for transporting the containers away from the transfer station.

[0006] The storage assembly may include a plurality of storage locations, which may be spaced vertically apart from each other. For example, the storage locations may be arranged in a series of vertically spaced horizontal rows or a series of vertical columns.

[0007] Optionally, the storage assembly may include tracks located adjacent the storage location.

[0008] The carrier is configured to transfer the container and is configured to retrieve one of the containers from one of the storage locations. Similarly, the carrier can be configured to store one of the containers in one of the storage locations.

[0009] The carrier may include a drive system configured to drive the carrier along the track to the first storage position so that the carrier can retrieve the first container.

[0010] Optionally, each vehicle may include a rechargeable power source for providing power to the drive system.

[0011] Each carrier may include a surface configured to support one of the containers.

[0012] The system may include a central controller configured to control operation of each of the plurality of vehicles.

[0013] Optionally, the drive system of each vehicle includes one or more rotatable elements. For example, the drive system may include a plurality of wheels or rollers.

[0014] The drive system may include a horizontal drive system and a vertical drive system.

[0015] Alternatively, the horizontal drive system can be configured to drive the vehicle along a horizontal surface. The vertical drive system can be configured to drive the vehicle vertically along a track. For example, the first storage location can be located above the horizontal surface, and the vertical drive system can be configured to drive the vehicle upward toward the first storage location.

[0016] The system may include a workstation for retrieving items from the container, and the first conveyor may be configured to convey the container from the transfer station to the workstation.

[0017] The first horizontal conveyor may be configured to receive the container and convey the container to the workstation along a first horizontal path. Optionally, the first horizontal path is in a first direction.

[0018] Optionally, the first horizontal conveyor comprises a loop, the loop comprising a first segment and a second segment, the first segment being configured to transfer containers away from the transfer station and the second segment being configured to transfer containers to the transfer station.

[0019] Optionally, the transfer station is configured to receive the container from the carrier and convey the container toward the first horizontal conveyor.

[0020] The transfer station may include a second horizontal conveyor configured to transfer containers along a second horizontal path toward the first horizontal conveyor. The second horizontal path may be transverse to the first horizontal path.

[0021] The transfer station may also include a guide configured to guide the carrier from the horizontal surface to a first transfer position located along the second horizontal conveyor. The system may be operable to transfer the first container from the first carrier to the second horizontal conveyor at the transfer position.

[0022] The transfer station may include one or more transfer locations vertically spaced apart from the first transfer location.

[0023] Optionally, the guide may include a first track for guiding the carrier from the horizontal surface to one of the transfer locations.

[0024] The first track of the guide may include a first vertical track configured to cooperate with the drive system to drive the carrier upward to one of the transfer positions.

[0025] The transfer station may include a third horizontal conveyor spaced apart from the second horizontal conveyor. The third horizontal conveyor may be operable to transfer the container along a third horizontal path toward the first horizontal conveyor.

[0026] Optionally, the transfer station includes a second vertical track adjacent to the third horizontal conveyor. The second vertical track can cooperate with the drive system to drive the carrier upward in the channel between the second horizontal conveyor and the third horizontal conveyor.

[0027] Each carrier may include a transfer mechanism configured to engage a container. The transfer mechanism may be configured to transfer the container between the carrier and the storage location.

[0028] Optionally, the transfer mechanism may be configured to transfer the first container from the first carrier toward the second horizontal conveyor.

[0029] The transfer mechanism may be configured to transfer the first container in a direction transverse to the second horizontal path as the first carrier transfers the container toward the second horizontal conveyor.

[0030] Optionally, the first horizontal conveyor comprises a plurality of vertically spaced overlapping conveyors forming a plurality of conveyor layers.

[0031] Optionally, the second horizontal conveyor comprises a plurality of vertically spaced overlapping conveyors. If the first and second conveyors each comprise a plurality of overlapping conveyor layers, each layer of the second conveyor may intersect one of the conveyor layers of the first horizontal conveyor.

[0032] According to yet another aspect, a method for storing or retrieving a plurality of containers is provided. The method uses a plurality of carriers that move between a storage location of the storage container and a transfer station. The container is transferred to the transfer station. From the transfer station, the container is transported to a workstation. At the workstation, an operator removes one or more items from the container or stores one or more items in the container.

[0033] Optionally, the method includes the step of controlling the plurality of carriers by driving a first carrier along a horizontal surface toward one of the storage shelves. The first carrier is then transferred upward from the horizontal surface to one of the storage locations so that the first carrier is aligned with the first container.

[0034] The step of transferring the container to the transfer station may include the step of driving a first carrier with the first container along a horizontal surface between the storage rack and the transfer station.

[0035] Optionally, the first carrier is transferred vertically between a horizontal surface and a transfer position at a transfer station.

[0036] The step of vertically transferring the first carrier between the horizontal surface and the transfer location may include driving the first carrier vertically upward along a guide adjacent the transfer location.

[0037] The step of transferring the first container may include the step of transferring the first container between the first carrier and a first conveyor of the transfer station.

[0038] The step of transferring the container may include transferring the first container in a first direction toward a first conveyor.

[0039] Optionally, the first container may be conveyed along the first conveyor in a second direction transverse to the first direction.

[0040] The method may include the steps of transferring the container from the first conveyor to the second conveyor. The second conveyor may be operated to convey the first container to the workstation. The second conveyor may convey the first container in a third direction transverse to the second direction.

[0041] Optionally, the step of conveying the first container includes conveying the first container to the workstation along a conveyor loop extending from the conveying station. The conveying step may also include returning the first container to the conveying station along the loop.

[0042] Optionally, the first carrier may be charged during the step of vertically transferring the first carrier between the horizontal surface and the transfer location.

[0043] The step of transferring the first container between the first carrier and the first conveyor may include transferring the first container to a conveyor mechanism operable between a first position in which the conveyor mechanism is disposed at a lower position below the first conveyor and a second position in which the conveyor mechanism is disposed above the first conveyor.

[0044] Optionally, the first container may be transferred onto the conveyor mechanism when the conveyor mechanism is in the first position.

[0045] The step of moving the conveyor mechanism to the second position may move the conveyor mechanism into engagement with the first container.

[0046] The method may include the step of actuating a transfer mechanism to transfer a first container across a first conveyor.

[0047] After the step of actuating the transport mechanism, the transport mechanism may be lowered to the first position.

[0048] Optionally, after the step of lowering the transfer mechanism to the first position, the first container may be transported away from the transfer position.

[0049] The first carrier may include a transfer assembly operable to transfer the container onto or off the carrier, and the step of transferring the first container between the first carrier and the first conveyor may include actuating the transfer assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The foregoing summary and the following detailed description of preferred embodiments of the invention will be best understood when read in conjunction with the accompanying drawings, in which: Figure 1 It is a plan view of the material handling system; Figure 2 yes Figure 1 an enlarged plan view of a portion of the material handling system shown; Figure 3 yes Figure 1 a side elevation view of a portion of a material handling system shown; Figure 4 yes Figure 1 An enlarged perspective view of a transfer station of a material handling system is shown; Figure 5 is used for Figure 1 A perspective view of a carrier of a material handling system is shown; Figure 6 yes Figure 5 an end view of the carrier shown; and Figure 7 yes Figure 5 A side elevation view of the vehicle is shown. DETAILED DESCRIPTION

[0051] The preferred embodiments of the present invention are now described in detail. Referring to the accompanying drawings, the same reference numerals in all views represent the same parts. As used in the description herein and throughout the claims that follow, the meanings of "a", "an", and "the" include plural references unless the context clearly dictates otherwise. In addition, as used in the description herein and throughout the claims that follow, the meaning of "in" includes "in" and "on", unless the context clearly dictates otherwise.

[0052] Referring now generally to the drawings and specifically to Figure 1, an apparatus for sorting or retrieving articles is generally indicated at 10. The apparatus 10 includes one or more mechanisms for retrieving articles from one of a plurality of locations, such as a storage area 25 located in a shelf 20. The retrieval mechanism may include one or more carriers that retrieve the articles from the storage location and deliver the articles to a transfer station 200, where the articles may be transferred to an alternate material handling system, such as a conveyor system. Additionally or alternatively, the articles may be transferred to the carriers at the transfer station so that the carriers may deliver the articles from the transfer station 200 to the shelf 20. Thus, the system 10 may include mechanisms for continuously storing articles in various storage areas and retrieving articles from various storage areas.

[0053] It should be understood that the various items and subcomponents of the overall system may be used alone or in conjunction with material handling systems that differ in structure or operation from the systems shown in the figures and described below.

[0054] Material handling system 10 may include any of a variety of different systems for storing items. For example, the material handling system may include a system including a plurality of autonomous vehicles, such as the system described in U.S. Pat. No. 11,254,504. The entire description of U.S. Pat. No. 11,254,504 is hereby incorporated herein by reference.

[0055] like Figure 1 As shown, the material handling system 10 may optionally include one or more racks 20. Each rack may include a plurality of storage locations 25. Optionally, the storage locations may be arranged in one or more vertical columns 22. For example, Figure 1 A plurality of racks 20 are shown, each of which may include a plurality of columns 22 , each of which includes a plurality of storage locations 25 .

[0056] Items handled by the system can be stored directly in the storage location. Alternatively, the items can be stored in boxes or large bags 55, and the storage location 25 can be configured to store large bags 55, such as Figure 3 Therefore, it should be understood that, unless otherwise stated in the following description, when referring to a large bag, the scope of the term "large bag" is sufficient to include containers for containing one or more items as well as items that are not necessarily contained in the container.

[0057] See again Figure 1, the system may include a plurality of shelves 20, which may be optionally positioned to form rows or aisles 50. For example, a first shelf 20a may be spaced apart from a second shelf 20b, thereby forming an aisle 50 between the two shelves. In particular, the first shelf 20a may be substantially parallel to the second shelf 20b to form an aisle of substantially uniform width. In addition, the system may include a plurality of shelves, thereby forming a plurality of aisles 50. The aisles 50 may be arranged in a series of parallel rows. However, it should be understood that if the system includes a plurality of shelves 20, the shelves may be arranged in various configurations, and if the system includes a plurality of aisles 50, the aisles do not need to be parallel.

[0058] Optionally, the system includes an automated component for storing and retrieving large bags to and from storage locations. One such automated component is an autonomous carrier. For example, as discussed further below, the automated component may include a plurality of autonomous carriers 100. In addition, the automated carriers 100 may be configured to transport large bags 55 to a workstation where one or more items may be removed from the large bag on one of the carriers 100. In one embodiment, an operator or an automated mechanism may remove items from a carrier. Alternatively, as described above, an automated mechanism may be configured to transport large bags 55 to a workstation where one or more items may be removed from the bag on one of the carriers 100. Figures 1 to 4 As shown, at a transfer station 200, the large bag 55 may be transferred to a conveyor system.

[0059] The system 10 and / or the various components of the system can be controlled by a central controller 90, such as a microcomputer. The central computer can receive signals from various components, such as sensors, and control various aspects of the system based on the signals received from the various components. The central controller can also store data regarding the location of various items to be removed from the system. In addition, the central controller can include data regarding the identification of items to be removed (such as a number of items to complete a customer order) and the quantity of these items. In this way, the central controller can control and coordinate the operation of the various components to arrange for the retrieval and processing of various items from storage locations.

[0060] Shelving System As described above, the system may include one or more racks 20 having a plurality of storage locations 25 . Figure 1 and Figure 2 Details of an exemplary storage rack 20 are shown. However, it should be noted that the system may include any of a variety of elements for organizing a plurality of storage locations 25.

[0061] See also Figure 2 and Figure 3 Each shelf may include a plurality of support legs and a plurality of brackets, the support legs extending substantially vertically, and the brackets extending substantially horizontally and interconnecting the support legs. The brackets may be planar elements forming the shelves, such that the shelves form storage locations 25. However, in Figure 2 In the illustrated embodiment, the horizontal brackets are L-shaped brackets that form horizontal crosspieces to support the edges of a large bag 55. The horizontal brackets may be spaced apart from one another at the height of the vertical legs to form columns 22 of vertically spaced storage locations 25.

[0062] As described above, the system may include a plurality of shelves spaced apart to form one or more aisles 50. Alternatively, see Figure 1 and Figure 3 , tracks 40 may be positioned along one or more shelves, and the tracks may be configured to guide carriers 100 vertically so that the carriers may be transported up and down along column 22 to a storage location in the column. In addition, it may be desirable to position a first track on one side of an aisle along a shelf (such as along shelf 20a) and a second track on the opposite side of the aisle along a shelf (such as along shelf 20b). Carriers 100 may be configured so that the carriers travel in aisle 50, traveling vertically along tracks on shelf 20a while traveling vertically along tracks on shelf 20b.

[0063] If the system employs one or more carriers and one or more racks, the racks may be configured to allow the carriers to travel underneath the racks 20 and through or along any aisles that may be incorporated into the system. Figure 2 , the carrier can travel along a path that extends along one or more segments that can be parallel or transverse to the channel. For example, the first carrier 100a is oriented to move horizontally along a path transverse to the length of the channel 50. The second carrier 100b is oriented to move horizontally along a path parallel to the length of the channel 50 below the shelf. In addition, the third carrier 100d is located in the channel 50 to climb up the vertical track along the shelf 20 on either side of the channel. The fourth carrier 100e is also located in the channel and has climbed up the track 40a, b to the storage position 25 in the upper part of the column 22. Finally, the fifth carrier 100f is located below the shelf 20 and is oriented at an intermediate position between the orientation of the carrier 100a and the orientation of the carrier 100b. In particular, the shelf can be constructed to facilitate the carrier to turn horizontally below the shelf. The fifth carrier 100f shows the carrier in the process of turning from the first path to the second path below the shelf.

[0064] Vehicles Figures 5 to 7 Shows Figures 1 to 4Detail of one of the carriers 100 shown. As described above, if the system includes a carrier, the structure of the carrier can vary. U.S. Patent No. 11,254,504 discloses details of an exemplary delivery carrier 100. The details of the disclosure of U.S. Patent No. 11,254,504 are hereby incorporated herein by reference. However, it should be understood that each feature of the carrier described in U.S. Patent No. 11,254,504 or discussed below is an optional feature that can be changed or eliminated depending on the application.

[0065] The vehicle 100 may be an autonomous system that includes an onboard power source for driving the vehicle. The vehicle may also include a communication system for wirelessly receiving and sending control signals between each vehicle and a control element, such as a central controller. In this way, the vehicle may receive control signals regarding the location to retrieve the item and the location to which the vehicle delivers the item.

[0066] The central controller may include any of a variety of control mechanisms, including but not limited to a central processing unit, such as a microprocessor. Various aspects of the controller may be embodied in hardware and / or software (including firmware, resident software, microcode, etc.), which are generally referred to herein as "circuits" or "modules". In addition, various aspects of the present invention may take the form of a computer program product on a computer-usable or computer-readable storage medium, which has a computer-usable or computer-readable program code embodied in the medium for use by an instruction execution system or in combination with it. In the context of this specification, a computer-usable or computer-readable medium may be any medium that is capable of containing, storing, conveying, propagating or transmitting a program for use by an instruction execution system, device or apparatus or in combination with it. These computer program instructions may also be stored in a computer-usable or computer-readable memory, which may instruct a computer or other programmable data processing device to operate in a particular manner, so that the instructions stored in the computer-usable or computer-readable memory form an article of manufacture including instructions for implementing the functions specified in one or more blocks of a flowchart and / or block diagram.

[0067] A computer usable or computer readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared or semiconductor system, apparatus or device. More specific examples (list) of computer readable media include: a hard disk, an optical storage device, a magnetic storage device, an electrical connection having one or more conductors, a portable computer diskette, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), optical fiber, and a compact disk read-only memory (CD-ROM).

[0068] The computer program code for performing the operations of the embodiments of the present invention may be written in an object-oriented programming language such as Java.RTM, Smalltalk or C++, etc. However, the computer program code for performing the operations of the embodiments of the present invention may also be written in a traditional procedural programming language such as the "C" programming language and / or any other low-level assembly language. It should also be appreciated that the functionality of any or all of the program modules may also be implemented using discrete hardware components, one or more application specific integrated circuits (ASICs), or programmed digital signal processors or microcontrollers.

[0069] Figure 3 The illustrated vehicle includes a horizontal drive assembly 120 for driving the vehicle 100 in a horizontal direction. The horizontal drive mechanism 120 can be configured to drive the vehicle along a track or along an open horizontal surface, such as a floor. For example, one option for the horizontal drive mechanism includes a plurality of rotatable elements, such as wheels or rollers. One or more drive mechanisms can be provided to rotate the rotatable elements. In addition, the rotatable elements can be rotated from side to side to turn the vehicle.

[0070] Alternatively, if Figures 5 to 7 As shown, the carrier may have a horizontal drive mechanism 120 formed by a plurality of rollers 122, 123, 124 that are rotatable about a first axis, such as about a wheel axle. In addition, the rollers 122, 123, 124 may be constrained to rotate about a single axis. For example, in Figures 5 to 7 In the illustrated embodiment, the horizontal drive mechanism 120 includes a pair of center rollers 124 and first and second sets of outer rollers 122, 123. The first set 122 is located in front of the center roller, while the second set of rollers 123 is located behind the center roller 124. The outer rollers 122, 123 may include rollers spaced apart along the length of the horizontal axle, such that each set of outer rollers includes a first roller 122a on one side of the carrier and a second roller 122b on the opposite side of the carrier, as shown. Figure 6 In addition, Figure 6 As shown, each set of outer rollers may include a pair of rollers 122b on each side of the carrier.

[0071] As described above, the vehicle 100 can have any of a variety of steering mechanisms for controlling the direction of travel of the vehicle. For example, an optional steering mechanism is a zero-turn mechanism that can turn the vehicle without substantially moving forward. Optionally, the zero-turn mechanism provides a means for turning the vehicle about a vertical axis extending through the vehicle.

[0072] The zero-turn mechanism includes a linkage that allows the wheels or rollers on one side of the vehicle to rotate at a different speed than the wheels or rollers on the opposite side of the vehicle. Optionally, the linkage allows the wheels or rollers on one side of the vehicle to rotate in a different direction than the wheels or rollers on the opposite side of the vehicle. In this way, by changing the speed and / or rotation direction of the wheels on one side of the vehicle relative to the speed and / or rotation direction of the wheels on the opposite side of the vehicle, the zero-turn mechanism changes the direction of travel and turns the vehicle. Optionally, the system may also include one or more guides 80 to guide or align the vehicle as it travels, and the vehicle may include a guide element that cooperates with the guide to align and / or guide the vehicle.

[0073] In addition to the horizontal drive mechanism 120, the carrier may also include a vertical drive mechanism 140 for vertically driving the carrier 100 within the shelf 20. In particular, as described above, the system may include a guide mechanism, such as a track 40, which is disposed near the shelf 20. The vertical drive mechanism 140 may be configured to cooperate with the vertical guide mechanism 40 to drive the carrier 100 vertically.

[0074] Figure 5 and Figure 6 An exemplary vertical drive mechanism 140 is shown, which includes a plurality of rotatable gears 145, however, it should be understood that the vertical drive mechanism 140 may include any of a variety of drive mechanisms for vertically driving a vehicle. Figure 5 , the vertical drive mechanism may include a drive gear 145 that rotates about a horizontal axis that is transverse to the horizontal rotation axis of the horizontal drive mechanism 120. Specifically, optionally, the carrier includes a pair of drive gears 145 that are spaced apart from each other such that the teeth of the first gear 145b protrude outwardly from a first side of the carrier, and the teeth of the second gear 145d protrude outwardly from a second side of the carrier, such as Figure 6 As shown. The first and second gears 145b, d can be driven synchronously. In addition, as Figure 5 As shown, the vehicle may include two pairs of vertical drive elements spaced apart from each other along the length of the vehicle. Specifically, optionally, the vehicle includes a first pair of vertical drive elements 145a, c at a first end of the vehicle and a second pair of vertical drive elements 145b, d at a second end of the vehicle.

[0075] See also Figures 1 to 3, the shelf 20 can be configured so that the track 40a on one shelf is spaced apart from the track 40b on the second shelf by a distance corresponding to the spacing between the first set of vertical drive elements 145a and the second set of drive elements 145b. In this way, the first vertical drive element 145a can cooperate with the first track 40a to drive the carrier upward along the first track 40a, and the second vertical drive element 145b can cooperate with the second track 40b to drive the carrier upward along the second track 40b. Optionally, the two vertical drive elements 145a, b are driven synchronously so that the carrier maintains a horizontal orientation when the carrier switches from horizontal motion to vertical motion.

[0076] The vertical drive mechanism 140 may optionally be configured such that the vertical drive mechanism has a substantially constant width when the vehicle transitions from horizontal motion to vertical motion. In this way, the vertical drive mechanism 140 does not need to be telescoped or extended outward to transition from horizontal to vertical drive. For example, see Figure 5 and Figure 6 , the forward climbing gears 145b and 145d each have a horizontal rotation axis, and the spacing between the horizontal rotation axes of the drive member 145b is fixed relative to the horizontal rotation axis of the drive member 145d while the vehicle is moving horizontally and climbing.

[0077] The carrier may also include an optional conveyor mechanism for conveying items between the carrier and a destination, such as a storage location. The conveyor mechanism 150 may be operable to convey items between the platform surface of the carrier and one of the plurality of destination areas 25. Figure 5 As shown, the platform surface is optionally defined by the outer surfaces of a plurality of rollers.

[0078] The conveyor mechanism 150 can be any of a variety of mechanisms for loading items onto the carrier and unloading items from the carrier to one of the storage areas. In addition, the conveyor mechanism 150 can be specifically customized for a particular application. In this example, the conveyor mechanism 150 includes one or more movable elements that are configured to engage items stored in the storage location and pull the items onto the carrier. More specifically, in this example, the carrier includes one or more movable elements that are configured to move toward a large bag in the storage location and releasably engage the large bag. After the one or more movable elements engage the large bag, each movable element moves away from the storage location, thereby pulling the large bag onto the carrier 100.

[0079] The movable element of the transport mechanism may be any of a variety of props, such as a rod, a bar, or another element configured to engage an object, such as a large bag. See, for example, Figure 5 and Figure 6, the conveying mechanism 150 may include one or more movable pins 152. In addition, the conveying mechanism may include a drive element for moving the pins 152. For example, optionally, the conveying mechanism 150 includes two drive elements in the form of an annular carrier, such as a drive belt or drive chain 154. Optionally, each pin 152 protrudes or extends inwardly toward the longitudinal centerline of the carrier. The conveying mechanism is preferably configured to cooperate with one of the large bags to releasably engage the large bag. For example, in this example, the pin 152 is configured to tightly fit with a groove on the large bag so that the conveying mechanism can engage the large bag. However, it should be appreciated that the conveying mechanism may include any of a variety of elements for engaging items to be conveyed to or from the carrier.

[0080] Input / output station See also Figure 1 and Figure 4 , the system includes an input / output station for loading containers onto or unloading containers from a carrier 100. For example, containers can be loaded onto a carrier to replenish the inventory of items stored in a shelf system. In such an application, the conveyor system 300 can automatically transport the container 55 to the input / output station 200, where the container is loaded onto the carrier 100. The carrier 100 then delivers the container 55 to the shelf 20 and transfers the container to the storage location 25. Alternatively, the carrier 100 can retrieve the container 55 from the storage location in the shelf 20 and deliver the container to the input / output station 200, where the container is transferred to the input / output station 200. The container 55 is then automatically transported away by the conveyor system 300 so that the container can be processed in a downstream process. For example, at a downstream station, an operator can retrieve one or more items from the container 55.

[0081] Alternatively, the conveyor system 300 may include one or more conveyor systems that form a loop so that the container 55 can be conveyed away from the transfer station input / output station 200 and then conveyed back to the input / output station 200. In this way, the conveyor system 300 may include one or more forward segments that convey the container 55 away from the input / output station 200 and one or more return segments that convey the container toward the input / output station 200. The aforementioned downstream station may be located along the forward or return segments.

[0082] The import / export station 200 includes one or more transfer stations 230 where containers are transferred between the import / export station 200 and a carrier. Figure 1 and Figure 4In the illustrated embodiment, the system includes a plurality of loading stations 230. For example, the import / export station 200 may include a pair of spaced apart conveyor assemblies 210, and each conveyor assembly may include one or more transfer stations 230. In this example, each conveyor 210 includes a plurality of transfer stations.

[0083] The input / output station 200 may include a single transfer conveyor 210; however, in this example, the station 200 includes a pair of conveyors. The transfer conveyors may be configured in a variety of configurations. For example, the conveyors may be arranged at an angle to each other. Alternatively, in the illustrated embodiment, the transfer conveyors 210 are separated by gaps and are substantially parallel to each other. The gaps formed between the conveyors 210 may form a channel 220 in which the delivery vehicle 100 operates, as discussed further below.

[0084] See also Figure 4 , each transfer conveyor 210 may include multiple stacked conveyors. For example, as shown in the figure, each transfer conveyor includes multiple layers, wherein each layer is a separate conveyor located above the next layer. For example, the transfer conveyor on one side of the channel 220 may include three layers, marked as 210A, 210B and 210C. Similarly, the main conveyor 300 may include multiple layers 300A, 300B and 300C, wherein each layer is aligned with one of the corresponding layers (such as conveyors 210A, 210B and 210C) from each transfer conveyor. Although the main conveyor 300 and the transfer conveyor 210 are shown as having three layers, it should be understood that the main conveyor and the transfer conveyor can have any number of layers depending on the application.

[0085] See also Figure 1 Each transfer conveyor 210 may include a plurality of loading stations 230 spaced apart along the length of the transfer conveyor. For example, each transfer conveyor 210 may include two loading stations 230. Figure 4 As shown, each layer of transfer conveyor 210A, 210B or 210C can have multiple loading stations. For example, conveyor 210A can include transfer stations 230A and 230H. In this way, each transfer conveyor 230 can have multiple overlapping transfer stations, such as 230A, 230B and 230C or 230D, 230E and 230F.

[0086] As described above, each delivery vehicle 100 may include a transfer mechanism 150 operable to transfer an item, such as a large bag 55, to a transfer conveyor 210 at a loading station 230. Figure 1 and Figure 4As shown, the loading station 230 may include a loading mechanism 235 that is operable to load articles onto the transfer conveyor 210. Specifically, the loading mechanism 235 is configured to transfer articles in a direction transverse to the direction of travel of the articles on the transfer conveyor. Figure 1 As shown, the transfer conveyor 210 can be operated in a first direction to move at a position indicated by T 2 Similarly, the transfer conveyor can be operated in the opposite direction to move the articles in the first direction. Figure 1 The winning bid is T 3 The loading mechanism 235 can be configured to move the article in the opposite direction of the direction T. 2 or T 3 Transfer the article to load the article onto the transfer conveyor. For example, the loading mechanism 235 can be parallel to T 1 Transfer items in the direction of

[0087] The loading mechanism 235 can be any of a variety of props for conveying items through a conveyor. For example, the loading mechanism can be a right-angle conveyor assembly. Specifically, the loading mechanism 235 can be one or more conveyor belts that are wound around a plurality of rollers or pulleys. The conveyor belt can be arranged in a direction opposite to the direction of travel T. 2 、T 3 Stretch in the opposite direction.

[0088] The loading mechanism 235 can be moved between a first position and a second position such that the loading mechanism is hidden or not in the path of motion of the transfer conveyor 210 in the first position. Thus, in the first position, the loading mechanism does not prevent movement of the transport conveyor 210 along the transport conveyor, such as along the length of the conveyor (e.g., direction T). 2 or T 3 In the second position, the loading mechanism may prevent movement along the length of the conveyor.

[0089] For example, the loading mechanism 235 can be a conveyor disposed between rollers of the transfer conveyor. The loading mechanism can be movable between a first position and a second position. In the first position, the loading mechanism 235 can be positioned below the top surface of the rollers of the transfer conveyor 210 so that an article, such as a large bag 55, can be loaded along the length of the transfer conveyor toward the main conveyor 300 or toward one of the loading stations 230 (i.e., direction T 2 or T 3 ) to move freely. In the second position, the loading mechanism can be positioned upwardly so that the top surface of the loading mechanism is raised above the transfer conveyor 210. In this way, the loading mechanism 235 can prevent the transfer of articles along the length of the transfer conveyor 210. In addition, in the raised position, the loading mechanism can be operated to transfer articles to the transfer conveyor so that the articles can be transferred by the transfer conveyor 210.

[0090] Although the loading mechanism has been described as a right angle conveyor having a raised position (in which the loading mechanism is operable) and a lowered position (in which the loading position is stowed or retracted), it should be understood that the transfer mechanism can be any of a variety of mechanisms for transferring articles along the width of the conveyor.

[0091] Charging components The transfer station 200 may optionally include a charging mechanism for charging the vehicle 100. The charging mechanism may be connected to a power source to supply a charging current to recharge the power source of the vehicle. For example, each vehicle optionally includes an onboard rechargeable power source. The rechargeable power source may be a rechargeable battery. However, in this example, the vehicle includes a power source that includes a plurality of ultracapacitors that can be quickly recharged. For example, the power source may include a plurality of supercapacitors or ultracapacitors sufficient to power the vehicle while it moves horizontally or vertically with a payload of 30 to 40 kg.

[0092] The charging mechanism can be any of a variety of elements for supplying a charging current to a vehicle. For example, in this example, the charging mechanism can be a charging rail that cooperates with electrical contacts on the vehicle 100 .

[0093] The charging rail may include one or more elongated conductive elements. The rail may form one or more channels or grooves that are configured to mate with electrical contacts of the vehicle. For example, the vehicle may include one or more charging contacts, such as brushes. The brushes may protrude outward from the vehicle. The brushes are oriented and configured to mate or mate with the charging rail. For example, the charging rail may be oriented horizontally, and the charging rail may protrude horizontally outward from the rear side of the vehicle so that the brushes protrude to make electrical contact with the charging rail when the vehicle is in the chassis.

[0094] operate The system 10 and various subassemblies described above may be configured to facilitate a variety of methods of operation related to material handling as described below.

[0095] The system 10 may include a plurality of autonomous vehicles 100 for delivering items to a transfer station 230. The vehicles may be configured to travel along a horizontal path 60, such as along a floor. Alternatively, the vehicles may travel along a floor to a storage area where multiple items are stored. For example, the multiple items may be stored in multiple containers, such as large bags. Alternatively, the large bags may be stored in multiple shelves 20, which are spaced apart to form longitudinally extending channels 50. The channels may be parallel to each other.

[0096] The carrier 100 may travel under one of the shelves 20 in a direction parallel to one of the aisles 50. The carrier 100 may travel under the shelf until the carrier reaches a destination column 22 in the shelf, which is a column in which an item is to be stored or retrieved.

[0097] Optionally, when the carrier reaches the destination column, the carrier can rotate or turn to change the direction of travel. For example, when the carrier is in the destination column, the carrier can change from a direction of travel parallel to the channel to a direction of travel transverse to the channel. Alternatively, the carrier can travel to the destination column under the shelf 20 along a path substantially perpendicular to the channel. After reaching the destination column, the carrier optionally travels perpendicular to the channel into the channel of the destination column.

[0098] In the passage, the carrier 100 optionally travels upward to a destination location 25 where items are to be stored or retrieved. The carrier 100 can be raised along the column 22 by an elevator or other mechanism. However, in this example, the carrier includes a vertical drive mechanism 140 that is operable to drive the carrier upward. In addition, the system can include a track or guide 40 located near the column, and the vertical drive mechanism 140 of the carrier can engage the track or guide to drive the carrier upward along the column to the destination location.

[0099] Once the carrier is raised to the destination, items such as large bags 55 can be transferred between the carrier and the destination. For example, the carrier can include a conveyor mechanism for conveying large bags, and the carrier can actuate the conveyor mechanism to convey the large bags from the carrier to the destination or to convey the large bags from the destination to the carrier.

[0100] After transferring the item between the vehicle and the destination, the vehicle may optionally travel down to a horizontal path, such as the ground. The vehicle may then travel horizontally along a path perpendicular to the passage.

[0101] The system may also include one or more transfer stations 200. The system may include methods for operating an autonomous vehicle at a workstation 200. For example, a vehicle 100 may travel along a horizontal path to carry an item, such as a large bag 55, to a transfer station 200. The vehicle may travel to a transfer station to align the vehicle with a predetermined location within the transfer station.

[0102] The system may optionally include a method for controlling a carrier to transfer an item, such as a large bag, at a transfer station 200. For example, the method may include the steps of driving the carrier 100 into the transfer station 200 and lifting the carrier upward. For example, the carrier may be lifted upward toward a transfer conveyor 210. Optionally, the input / output station 200 may include one or more transfer stations 230, and the method may include the steps of lifting the carrier so that the large bag on the carrier is positioned at the transfer station 230.

[0103] Optionally, the step of lifting the carrier 100 may include the step of driving the carrier upward along the track 250. The track may include a first pair of spaced apart track segments and a second pair of spaced apart rear track segments. The method may include the steps of driving the rear edge of the carrier upward along the rear track segment and driving the front edge of the carrier upward along the front track segment. For example, Figure 4 As shown, vertical tracks 250 may be located near the transfer station 230. The pair of rear tracks may be disposed on one side of the passage adjacent to the sides of the loading stations 230D, 230E, and 230F, and the pair of front tracks may be disposed on the other side of the passage adjacent to the loading stations 230A, 230B, and 230C. In this way, the delivery vehicle may be moved vertically within the passage to align the delivery vehicle with one of the loading stations.

[0104] Optionally, the step of driving the vehicle 100 upward along the track 250 may include the step of rotating a vertical drive gear 145 of the vehicle about an axis transverse to the rotational axis of a plurality of drive elements that drive the vehicle along the horizontal surface. The step of driving the vehicle upward along the track may optionally include the step of driving the vertical drive gear in a first direction to travel upward along the track 250. By driving the vertical gear in the first direction, the vertical drive gear is driven upward along the track.

[0105] The method may also include the steps of transferring the article between the delivery carrier 100 and the loading station 230 after the carrier is aligned with the loading station. The transfer step may include the steps of operating the transfer mechanism on the delivery carrier to move the article between the carrier and the loading station 230. Alternatively or additionally, the transfer step may include the steps of actuating the transfer mechanism of the input / output station. For example, the transfer step may include the steps of driving the transfer mechanism of the delivery carrier to transfer the container 55 from the carrier toward the loading station 230. Once a portion of the container 55 is loaded onto the loading station, the loading mechanism 235 can transfer the container across the width of the transfer conveyor 210 to load the container onto the transfer conveyor. Similarly, the method may include the steps of loading the container 55 onto the delivery carrier by operating the loading mechanism to transfer the container across the width of the conveyor toward the delivery carrier. Then, the transfer mechanism 150 of the carrier is operated to load the container onto the delivery carrier.

[0106] The step of operating the loading mechanism 235 may include the step of raising the loading mechanism above the top surface of the transfer conveyor.

[0107] Although the step of transferring the container between the delivery vehicle and the transfer conveyor can include both the step of operating the transfer mechanism 150 on the delivery vehicle and the step of operating the loading mechanism 235, it should be understood that the method is not limited to utilizing the transfer mechanism on the delivery vehicle and a separate loading mechanism on the input / output station. Instead, the transfer mechanism 150 on the delivery vehicle can be configured to transfer the container 55 across the width of the transfer conveyor. Alternatively, the loading mechanism 235 can be configured to engage the container so that the loading mechanism can transfer the container onto or off the delivery vehicle without operating the transfer mechanism on the delivery vehicle.

[0108] like Figure 1 and Figure 4 As shown, the method may include the following steps: transferring articles between the main conveyor 300 and the transfer conveyor 210, the main conveyor being configured to transfer articles in a first direction, such as T1, and the transfer conveyor being configured to transfer articles in a second direction, such as T2 or T3, transverse to T1. The step of transferring articles between the main conveyor 300 and the transfer conveyor 210 may include the following steps: operating a right-angle transfer mechanism 320. The right-angle transfer mechanism 320 may be a component similar to the above-mentioned loading mechanism 235.

[0109] As described above, the method may include the step of transferring the container between the input / output station 200 and the main conveyor 300. For example, the step of transferring the container may include the step of transferring the container along a first path at the input / output station toward the main conveyor 300. The method may include the step of operating a right-angle transfer mechanism to transfer the container to the main container.

[0110] The method may optionally include the step of conveying the container away from the import / export station 200. For example, the method may include the step of conveying the container away from the import / export station along one or more conveyor segments. Optionally, the method may include the step of conveying the container toward the import / export station 200 after the step of conveying the container away from the import / export station 200 along one or more conveyor segments. Thus, the method may include the step of transporting the container along a loop extending from the import / export station and returning to the import / export station. The method may also include the step of conveying the container along the loop to a workstation so that an operator can load or remove items from the container.

[0111] The system may optionally include a method for charging an autonomous material handling vehicle. The method may include the steps of driving the vehicle 100 to the input / output station 200 to deliver an item. The vehicle may include electrical contacts, and the input / output station may include a charging element for supplying a charging current. The method may include the steps of electrically connecting the electrical contacts of the vehicle to the charging element. For example, the connecting step may include the steps of biasing the charging element toward the charging contacts, and / or biasing the charging contacts toward the charging element.

[0112] In addition, the connection method may include the following steps: driving the carrier toward the charging element to drive the electrical contacts to electrically connect with the charging element. Optionally, the method includes the following steps: automatically adjusting the height of the charging element relative to the charging contacts when the charging contacts move to electrically engage with the charging element. In addition, the method may include the following steps: automatically adjusting the lateral positioning of the charging contacts relative to the charging element when the charging contacts move to electrically engage with the charging element.

[0113] The method of charging a vehicle may optionally include the step of vertically lifting the vehicle while continuing to charge the vehicle. For example, the method may include the step of maintaining electrical engagement between the electrical contacts of the vehicle and the charging element as the vehicle moves upward. In addition, the charging current may be continuously supplied to the charging element as the vehicle moves upward at the input / output station 200. In addition, the charging current supplied to the charging element may be maintained while the vehicle remains at the loading station 230, so that the charging current may be supplied to the vehicle while the conveying mechanism conveys items to or from the vehicle. The charging current may also be supplied to the vehicle while the vehicle is lowered downward. The method may optionally include the step of disengaging the vehicle from the charging element by driving the vehicle away from the charging element.

[0114] Therefore, it should be understood that the present invention is not limited to the particular embodiments described herein, but is intended to include all changes and modifications within the scope and spirit of the present invention as set forth in the claims.

Claims

1. A material handling system, comprising: a plurality of storage locations spaced vertically apart from one another; Tracks located near storage locations; a plurality of containers in a storage location; A plurality of carriers configured to transport containers, wherein each carrier is operable to retrieve one of the plurality of containers from one of the storage locations or to store one of the plurality of containers to one of the storage locations, wherein each carrier comprises: a drive system configured to drive the carrier along the track to a first of the storage locations to position the carrier to retrieve a first of the containers from the first storage location; and A power supply for supplying power to the drive system; a first horizontal conveyor configured to receive the container and convey the container along a first horizontal path to a workstation where an operator can retrieve one or more items from the container, wherein the first horizontal path is in a first direction; A transfer station configured to receive the container from the carrier and to transfer the container toward the first horizontal conveyor, wherein the transfer station comprises: a second horizontal conveyor configured to transfer containers along a second horizontal path toward the first horizontal conveyor, wherein the second horizontal path is transverse to the first horizontal path; and A guide is configured to guide the carrier from the horizontal surface to a first transfer location located along the second horizontal conveyor, wherein the system is operable to transfer the first container from the first carrier to the second horizontal conveyor at the transfer location.

2. The system of claim 1, wherein the storage locations are arranged in a series of columns or vertically spaced rows.

3. A system according to claim 1 or 2, comprising one or more transfer locations vertically spaced apart from the first transfer location.

4. The system of claim 3, wherein the guide comprises a first track for guiding the carrier from the horizontal surface to one of the transfer locations.

5. The system of claim 4, wherein the first track of the guide comprises a first vertical track configured to cooperate with the drive system to drive the carrier upward to one of the transfer positions.

6. A system according to any one of claims 1 to 5, wherein the transfer station includes a third horizontal conveyor, which is separated from the second horizontal conveyor so as to form a channel between the second horizontal conveyor and the third horizontal conveyor, wherein the third horizontal conveyor is configured to transfer containers toward the first horizontal conveyor along a third horizontal path.

7. A system according to claim 6, wherein the transfer station includes a second vertical track adjacent to the third horizontal conveyor, wherein the second vertical track is cooperable with the drive system to drive the carrier upward in the channel between the second horizontal conveyor and the third horizontal conveyor.

8. The system of any one of claims 1 to 7, wherein each carrier includes a transfer mechanism configured to engage a container, wherein the transfer mechanism is configured to transfer the container between the carrier and the storage location.

9. The system of claim 8, wherein the transfer mechanism is configured to transfer the first container from the first carrier toward the second horizontal conveyor.

10. The system of claim 8 or 9, wherein the transfer mechanism is configured to transfer the first container in a direction transverse to the second horizontal path when the first carrier transfers the container toward the second horizontal conveyor.

11. A system according to any one of claims 1 to 10, wherein the first horizontal conveyor includes a plurality of vertically spaced overlapping conveyors to form a plurality of conveyor layers, and the second horizontal conveyor includes a plurality of vertically spaced overlapping conveyors, each conveyor intersecting one of the conveyor layers of the first horizontal conveyor.

12. The system of any one of claims 1 to 11, wherein each carrier comprises a surface configured to support one of the containers.

13. The system of any one of claims 1 to 12, comprising a central controller configured to control the operation of each of the plurality of vehicles.

14. The system of any one of claims 1 to 13, wherein the drive system comprises one or more rotatable elements.

15. The system of claim 14, wherein the rotatable element is a wheel or a roller.

16. The system of any one of claims 1 to 15, wherein the power source is rechargeable.

17. A system according to any one of claims 1 to 16, wherein the drive system includes a horizontal drive system and a vertical drive system, wherein the horizontal drive system is configured to drive the vehicle along a horizontal surface, and wherein the vertical drive system is configured to drive the vehicle vertically along a track, wherein the first storage position is located above the horizontal surface, and the vertical drive system is configured to drive the vehicle upward toward the first storage position.

18. The system of any one of claims 1 to 17, wherein the first horizontal conveyor comprises a loop including a first segment configured to transfer containers away from a transfer station and a second segment configured to transfer containers to a transfer station.

19. A method for storing or retrieving a plurality of containers at a plurality of storage locations in one or more storage racks, comprising the steps of: Controlling a plurality of independently operable carriers to deliver containers to or retrieve containers from a storage location, wherein the controlling step comprises the following steps: driving a first one of the carriers along the horizontal surface toward one of the storage shelves; transferring the first carrier from the horizontal surface upwardly to one of the storage locations so that the first carrier is aligned with the first container in the container; driving a first carrier with a first container along a horizontal surface between the storage rack and the transfer station; vertically transferring the first carrier between the horizontal surface and a transfer position at the transfer station; transferring a first container between a first carrier and a first conveyor of a transfer station; controlling the first conveyor to convey the first container from the transfer position toward the workstation or from the workstation and toward the transfer position; One or more items are retrieved from or stored in a first container at the workstation.

20. The method of claim 19, wherein the step of vertically transferring the first carrier between the horizontal surface and the transfer location may include the steps of: The first carrier is driven vertically upward along the guide adjacent the transfer location.

21. The method of claim 19 or 20, wherein the step of transferring the container comprises: The first container is transferred in a first direction toward a first conveyor.

22. The method of claim 21, wherein the step of controlling the conveyor comprises: The first container is conveyed along the first conveyor in a second direction transverse to the first direction.

23. The method according to claim 22, comprising the steps of: The container is transferred from the first conveyor to a second conveyor operable to convey the first container to the workstation, wherein the second conveyor conveys the first container in a third direction transverse to the second direction.

24. The method according to any one of claims 19 to 23, wherein the step of delivering the first container comprises the steps of: conveying the first container to the workstation along a conveyor loop extending from the transfer station; and The first container is returned along the loop to the transfer station.

25. The method according to any one of claims 19 to 24, comprising the steps of: The first carrier is charged during the step of vertically transferring the first carrier between the horizontal surface and the transfer location.

26. The method of any one of claims 19 to 25, wherein the step of transferring the first container between the first carrier and the first conveyor comprises: The first container is transferred to a transfer mechanism operable between a first position in which the transfer mechanism is disposed at a lower position below the first conveyor and a second position in which the transfer mechanism is disposed above the first conveyor.

27. The method of claim 26, wherein the step of transferring the first container to a conveyor mechanism comprises: When the conveyor mechanism is in the first position, a first container is transferred onto the conveyor mechanism.

28. The method according to claim 27, comprising the steps of: Translating the conveyor mechanism to a second position moves the conveyor mechanism into engagement with the first container.

29. The method according to claim 28, comprising the steps of: The transfer mechanism is actuated to transfer the first container across the first conveyor.

30. The method according to claim 29, comprising the steps of: After the step of actuating the conveyor mechanism, the conveyor mechanism is lowered.

31. The method of claim 30, wherein the step of transporting the first container away from the transfer location occurs after the step of lowering the transfer mechanism.

32. The method of any one of claims 19 to 31, wherein the first carrier includes a transfer assembly operable to transfer the container onto or off the carrier, and wherein the step of transferring the first container between the first carrier and the first conveyor comprises: Actuate the transfer assembly.

33. A transfer station for a material handling system configured to store a plurality of containers, comprising: a plurality of carriers, wherein each carrier comprises a horizontal drive mechanism for driving the carrier along a horizontal surface and a vertical drive mechanism for driving each carrier vertically; a first conveyor having a loading station, wherein the first conveyor is operable in a first direction to transfer articles away from the loading station; a first track located adjacent to the loading station and cooperable with a vertical drive mechanism of the delivery vehicle to transfer a leading edge of the delivery vehicle; as well as A second track is spaced apart from the first track and is cooperable with the vertical drive mechanism of the delivery vehicle to transfer the trailing edge of the delivery vehicle.

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