Systems, apparatus, and methods for high efficiency logistics towers

Abstract

A storage system comprising a three-dimensional structure comprising an array of cells, the array of cells comprising: a plurality of cells configured to hold separate storage bins for extraction, the array of cells forming a plurality of storage layers respectively located at different heights within the three-dimensional structure; and a second plurality of cells positioned relative to each other to form a plurality of shafts located within the three-dimensional structure. The storage system includes a plurality of in-tower robots located atop the three-dimensional structure. Each of the in-tower robots is configured to move laterally atop the three-dimensional structure between a plurality of different positions atop the three-dimensional structure, the plurality of different positions including at least a first position above a first shaft included in the plurality of shafts and a second position above a second shaft included in the plurality of shafts.

Description

Background of the Invention 1. Technical Field This invention generally relates to storage systems based on logistics towers. More specifically, at least one embodiment relates to a system, apparatus, and method for a storage system based on a high-efficiency logistics tower. 2. Background Technology Today, a wide variety of automation solutions are employed in material handling logistics hubs such as distribution centers, fulfillment centers, and micro-fulfillment centers. Some known solutions employ a three-dimensional grid structure arranged as cells, through which retrieval vehicles operate to access storage units for storing and retrieving materials located in bins distributed throughout the structure. In many cases, cells are organized such that vertical columns in the structure are positioned for retrieval vehicle operations, allowing the retrieval vehicle to access storage containers in one or more bays (or storage cells) positioned horizontally around the retrieval column at each level. The three-dimensional grid structure may include multiple vertical retrieval columns, with an associated, accessible bay surrounding each retrieval column at each individual level of the structure. Typically, the grid locations including the vertical retrieval columns are combined with adjacent storage cells accessed via the retrieval columns to form groups of cells within the grid. For example, Figure 1A and Figure 1B Top views of two different cell groups 19 and 29 are shown, respectively, in an existing grid structure used for material storage. Each cell group includes an elevator cell 17 and multiple storage cells 21. Figure 1A In this context, cell group 19 comprises a total of three storage cells 21, with one storage cell positioned on each of three of the four sides of elevator cell 17. Figure 1B In this embodiment, cell group 29 comprises a total of four storage cells 21, with one storage cell located on each of the four sides of the elevator cell 17. In these prior art solutions, cell groups 19 and 29 comprise adjacent storage cells at a single-layer cell depth. That is, the elevator cell 17 provides access to individual cells located on each of the three or four sides of the elevator cell 17. According to these solutions, multiple sets of these single-depth cell groups 19 and 29 are combined to form a cell grid located at various layers of the vertical storage structure.

[0002] The multi-layered, high-density nature of these vertical storage structures increases the amount of material that can be stored on a given plot of land, or square feet (“footprint”). However, despite these structures improving storage efficiency or storage density for a given geographic footprint, inefficiencies still exist. For example, Figure 2 Provided designs with different in Figure 1A and Figure 1BThe image shows a top view of a complete layer of a conventional vertical storage structure 11, cell groups 19 and 29. When viewed from above, the storage grid is 17 by 18 grids. This storage grid includes elevator cells 17, storage cells 21, and unoccupied cells 23. Each associated cell group 19, 29 is identified by horizontal and vertical lines that indicate the horizontal travel path (or range) of an extraction device (e.g., a grid robot at each layer). For example, cell group 19 includes elevator shaft 17 and three single-depth storage cells 21 arranged on three sides of elevator shaft 17. Cell group 29 includes elevator shaft 17 and four single-depth storage cells 21 arranged on four sides of elevator shaft 17.

[0003] Although Figure 2 The example demonstrates a single layer in a multi-tiered storage array, but the same layout can be found in every storage layer. This adds more unused space to each layer included in the storage array, exacerbating inefficiencies. For example, using... Figure 2 The 17x18 cell array created by a single-depth storage cell shown includes fourteen unused spaces. A ten-layer storage array constructed in this way includes 140 unused cells.

[0004] Therefore, even though the goal of these vertical storage structures is a compact, high-density footprint, unused, unoccupied cells 23 still result from the geometry available when using cell groups 19, 29 as building blocks for the entire cell array to assemble the storage grid 11. Furthermore, the geometry provided by cell groups 19, 29 limits the number of storage cells a single retrieval device can access to a maximum of four. Thus, using conventional single-depth cell groups 19, 29 in the storage grid increases the number of retrieval devices required in any given-size array.

[0005] Typically, conventional vertical storage structures include a lower level for wheeled robotic vehicles to traverse. These vehicles operate to transfer materials to and from retrieval units at the bottom of the lift shaft. They also shuttle between the lift shaft and available material unloading and retrieval locations within the vertical storage structure. These vehicles need to operate on a set of tracks or rails. Furthermore, sophisticated software logic must be used to precisely control the vehicle operation to avoid collisions and / or delays between multiple vehicles on the same track or in the same area.

[0006] While the speed of material movement in logistics hubs is important, the aforementioned drawbacks cannot be avoided by using these conventional methods.

[0007] Therefore, there is a need for solutions to increase the storage density of grid-based material handling logistics hubs. According to some embodiments, storage density is increased when the geometry of the cell groups used as building blocks includes multiple double-depth storage cell groups in a selected configuration.

[0008] Designs to improve the operational efficiency of grid-based material handling logistics towers are also needed. According to some embodiments, grid-based material handling logistics towers achieve significant improvements in operational efficiency by combining a winch-based elevator system with a dynamic conveyor system located beneath a multi-layered storage cell array leading to the retrieval location. Some of these embodiments eliminate the need for robotic flatbed carts to shuttle and transport materials beneath the storage cell array. Eliminating the robotic carts can significantly increase the operational speed of material transfer within the material handling logistics tower. The applicant has found that, in various embodiments, combining a winch-based elevator with a conveyor system, coupled with a storage cell array using three-compartment, double-depth storage cells, can optimize the overall system speed for material handling storage and retrieval.

[0009] According to one aspect, a storage system includes a three-dimensional structure comprising a cell array comprising: a first plurality of cells configured to hold independent storage bins for retrieval, the cell array forming a plurality of storage layers located at different heights within the three-dimensional structure; and a second plurality of cells positioned relative to each other to form a plurality of shafts located within the three-dimensional structure. The plurality of shafts are configured to allow access to storage cells included in the first plurality of cells located at each of the plurality of storage layers. The storage system also includes a material transfer layer located below the plurality of storage layers. The material transfer layer includes a transport system configured to move the individual storage bins in such a way that: a) they are moved from an unloading station to a location below the plurality of shafts; and b) they are moved from a location below the plurality of shafts to a retrieval station. The storage system also includes a plurality of towerbots located on top of the three-dimensional structure. Each of the plurality of towerbots includes a vertical lifting system comprising a bin transporter. Multiple tower robots are configured to move a bin transporter vertically within multiple shafts to align the bin transporter with a plurality of cells located at different heights. Each of these tower robots is configured to move laterally on top of the three-dimensional structure between multiple different positions, including at least a first position above a first shaft included in the plurality of shafts and a second position above a second shaft included in the plurality of shafts.

[0010] According to some embodiments, with the in-tower robot in a first position, the vertical lifting system is configured to position the bin transporter within the first shaft adjacent to a first group of storage cells located at a selected height, including different heights. The first group of storage cells includes at least one inner cell configured to hold an independent storage bin for later retrieval. The at least one inner cell includes a first side and a second side opposite the first side, the first side being adjacent to the lifting cell where the bin transporter is located at the selected height. With the bin transporter positioned adjacent to the first group of storage cells, the bin transporter is configured to retrieve the first storage bin located in the at least one inner cell for vertical transport from the selected height to a material transfer layer, whereby the bin transporter releases the first storage bin into the transport system, thereby allowing the first storage bin to move from a position below the first shaft. The in-tower robot is configured to move from the first position to a second position on top of the three-dimensional structure to enter a second shaft to retrieve a second storage bin and deliver it to the transport system.

[0011] According to some embodiments, each of a plurality of in-tower robots is configured to raise and lower an associated bin transporter between a fully raised position and a fully lowered position. Each of the plurality of in-tower robots includes a plurality of wheels configured to engage the three-dimensional structure and propel the respective in-tower robot between multiple different positions on top of the three-dimensional structure. Further, when the associated bin transporter is in the fully raised position and the associated bin transporter has firmly gripped the storage bin, the lower portion of the storage bin extends below the plurality of wheels of the respective in-tower robot.

[0012] According to some other embodiments, the storage cell group includes at least one double-depth storage cell group, which includes at least one inner cell and an outer cell. The outer cell included in the at least one double-depth storage cell group is positioned adjacent to a second side of the at least one inner cell. When the bin transporter is positioned adjacent to the storage cell group, the bin transporter is configured to extract the storage bin located in the outer cell for vertical transport from a selected height to a material transfer layer. The at least one inner cell is one of a plurality of inner cells included in the storage cell group, and the outer cell is one of a plurality of outer cells included in the storage cell group. The storage cell group includes a plurality of double-depth storage cell groups, each double-depth storage cell group including: a) one of a plurality of inner cells, each inner cell having a corresponding first side and a corresponding second side opposite to the corresponding first side, the corresponding first side being adjacent to the elevator cell where the bin transporter is located at the selected height; and b) one of a plurality of outer cells, each outer cell positioned adjacent to a corresponding second side of a corresponding inner cell included in the corresponding double-depth storage cell group.

[0013] According to another aspect, a method for storing and retrieving materials is provided. According to these embodiments, a plurality of storage cells are arranged together at different heights within a three-dimensional structure. The plurality of storage cells are configured to maintain independent storage bins for retrieval. A plurality of elevator cells are positioned relative to each other to form a plurality of shafts located within the three-dimensional structure. The plurality of shafts are configured to allow access to the storage cells included within the plurality of storage cells at each of the different heights. A material transfer layer is positioned below the plurality of storage cells and the plurality of elevator cells. The material transfer layer includes a transport system configured to move the individual storage bins in such a way that: a) they move from a loading station to a position below the plurality of shafts; and b) they move from the position below the plurality of shafts to a retrieval station to store and retrieve materials from the individual storage bins. A plurality of in-tower robots are positioned on top of the three-dimensional structure, each of the plurality of in-tower robots including a vertical lifting system comprising a bin transporter. The plurality of in-tower robots are configured to move the bin transporter vertically within the plurality of shafts to align the bin transporter with the plurality of storage cells located at different heights.

[0014] According to these embodiments, each of these tower robots is configured to move laterally on top of the three-dimensional structure between multiple different positions, including at least a first position above a first shaft included in a plurality of shafts and a second position above a second shaft included in a plurality of shafts. The vertical lifting system is configured to position a bin transporter in the first shaft adjacent to a first group of storage cells located at a selected height among the different heights, such that, when the bin transporter is positioned adjacent to the first group of storage cells, the bin transporter is positioned to extract a first storage bin located in the first group of storage cells for vertical transport from the selected height to a material transfer layer, so that the bin transporter releases the first storage bin into the transport system, thereby allowing the first storage bin to move from a position below the first shaft. The tower robot is configured to move from the first position to the second position on top of the three-dimensional structure to enter the second shaft to extract a second storage bin and deliver the second storage bin to the transport system.

[0015] According to another embodiment, the transport system includes a conveyor system comprising multiple motorized conveyor tiles. According to yet another embodiment, the transport system includes a shuttle system configured to move individual storage bins on a material transfer layer. The shuttle system includes multiple shuttles configured to travel along a horizontal shuttle grid to receive individual storage bins from a bin transporter.

[0016] According to another aspect, an in-tower robot for a storage array including multiple lift shafts located above a transport system. According to some embodiments, the in-tower robot includes a frame, a lifting system fixed to the frame, and a bin transport assembly coupled to the vertical lifting system. The bin transport assembly includes: a trolley and a bin transporter coupled below the trolley; a wheel assembly extending below the frame; and a drive system configured to rotate the wheel assembly to move the in-tower robot from a first position above a first lift shaft (among the multiple lift shafts) to a second position above a second lift shaft (among the multiple lift shafts), the first lift shaft being different from the second lift shaft.

[0017] According to some embodiments, the lifting system is configured to move the bin transporter assembly vertically within a first lift shaft to align the bin transporter with a first storage cell group positioned adjacent to the first lift shaft. The bin transporter, positioned adjacent to the first storage cell group, is configured to operate to retrieve a first storage bin and move it vertically within the first lift shaft to lower the first storage bin to the transport system and release it to the transport system for horizontal transport. According to these embodiments, an in-tower robot is configured to move from a first position to a second position on top of the storage array, and then move the bin transporter assembly vertically within a second lift shaft to align the bin transporter with a second storage cell group positioned adjacent to the second lift shaft to retrieve and deliver the second storage bin to the transport system. Attached Figure Description

[0018] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component shown in the various figures is represented by similar numbers. For clarity, not every component in every figure will be labeled. In the drawings: Figure 1A and Figure 1B This demonstrates a group of cells used in a material handling and storage grid according to a standard scheme. Figure 2 A top view of a material handling and storage grid according to a standard scheme is shown; Figure 3A and Figure 3B A group of cells is shown in a material handling and storage grid used in a logistics hub, according to one embodiment; Figure 4 A top view of a material handling and storage grid of a logistics hub according to one embodiment is shown; Figure 5 A top view of a logistics hub according to one embodiment is shown; Figure 6A perspective view of a logistics hub according to one embodiment is shown; Figure 7 A top view of a logistics hub according to one embodiment is provided; Figure 8 Provided according to one embodiment includes Figure 5 A detailed view of the logistics hub; Figure 9A and Figure 9B A model cell group is shown according to one embodiment for use in a material handling and storage grid in a logistics hub; Figure 10 A partial view of a logistics hub according to one embodiment is shown; Figure 11 A tower robot according to one embodiment is shown; Figure 12 Showing Figure 11 A partial view of the robot inside the tower; Figure 13 A bin handling machine according to one embodiment is shown; Figure 14 A bin handling assembly according to one embodiment is shown; and Figure 15 A plan view of a logistics hub according to one embodiment is shown. Detailed Implementation

[0019] The application of this invention is not limited to the details of the construction and the arrangement of components set forth in the following description or shown in the accompanying drawings. The invention can have other embodiments and can be practiced or implemented in a variety of different ways. Similarly, the wording and terminology used herein are for descriptive purposes and should not be considered limiting. The terms "comprising," "including," or "having," "containing," "involving," and variations thereof as used herein are intended to cover the items listed thereafter and their equivalents, as well as additional items.

[0020] refer to Figure 3A The image shows a top view of a first cell group 39 in a material handling storage grid used in a logistics hub, according to some embodiments. The first cell group 39 includes an elevator cell 37 and a plurality of storage cells 31. In the illustrated embodiment, the first cell group 39 includes a single storage cell positioned adjacent to a first side of the elevator cell 37 and a pair 45 of double-depth storage cells positioned adjacent to a second side of the elevator cell 37. In this configuration, each cell has a parallelogram shape when viewed from above, and the first and second sides of the elevator cell 37 are positioned adjacent to each other but orthogonally. When viewed from above, this gives the first cell group 39 an overall L-shape.

[0021] refer to Figure 3B The image shows a top view of a second cell group 49 in a material handling storage grid used in a logistics hub according to some embodiments. The second cell group 49 includes elevator cells 37 and a plurality of storage cells 31. In the illustrated embodiment, the second cell group 49 includes a single storage cell 31 positioned adjacent to a first side of the elevator cell 37, a first double-depth storage cell pair 47A positioned adjacent to a second side of the elevator cell 37, and a second double-depth storage cell pair 47B positioned adjacent to a third side of the elevator cell 37. In this configuration, each cell has a parallelogram shape when viewed from above. The first and second sides of the elevator cell 37 are positioned adjacent to but orthogonal to each other. The third side of the elevator cell 37 is positioned adjacent to and orthogonal to the first side and opposite to the second side. In this embodiment, the second cell group 49 has an overall T-shape when viewed from above, wherein the single storage cell 31A is oriented at a 90-degree angle to each of the first double-depth storage cell pair 47A and the second double-depth storage cell pair 47B.

[0022] Figure 3B The cell group 49 shown is referred to as a three-compartment double-depth configuration because it includes at least one storage cell on three of the four sides of the elevator cell 37 and includes at least one pair of double-depth storage cells. In the illustrated embodiment, cell group 49 includes two pairs of double-depth storage cells.

[0023] refer to Figure 4 This image shows a top view of a material handling and storage grid of a logistics hub according to some embodiments. In different embodiments, the logistics hub includes a logistics tower having multiple vertically positioned members, such as... Figure 4 The mesh layers are configured as shown in the image. As described below, multiple such mesh layers are used... Figure 4 The logistics tower with its grid-layer configuration shown also includes a material exchange layer for loading newly received materials into and removing materials from the logistics hub. The features included in the material exchange layer are described in more detail below and can vary depending on whether the logistics hub is a warehousing facility, distribution center, fulfillment center, or micro-fulfillment center. For example, warehousing or distribution centers are configured for bulk unloading and retrieval by trailer trucks or other high-capacity material transport vehicles. In contrast, the typical operation of a micro-fulfillment center involves end consumers or last-mile delivery personnel picking up materials at the logistics hub.

[0024] For example, as shown and described in jointly owned U.S. Patent Publication No. 2022 / 0194699, some solutions provide logistics tower-based storage systems that achieve a compact footprint through tower configuration and high-speed material handling through winch-based in-tower robot drive systems. The disclosure of U.S. Patent Publication No. 2022 / 0194699, entitled "Logistics Tower," published June 23, 2022, is incorporated herein by reference in its entirety.

[0025] In the illustrated embodiment, the material handling storage grid is 16 cells wide by 16 cells deep. However, depending on the embodiment, the material storage grid may include a smaller or a larger number of storage cells. Figure 4 A coordinate system A is included as a reference, which includes an x-axis and a y-axis. Additionally, the material handling and storage grid can be configured with asymmetrical dimensions. For example, in some embodiments, depending on the implementation, the grid may include a larger number of cells in the x-direction and a smaller number of cells in the y-direction, and vice versa. That is, the number of cells in the x-direction and the y-direction do not need to be equal. Furthermore, in some embodiments, the number of cells in either or both of the x-direction and the y-direction may include an odd number of cells.

[0026] In addition, it has multiple such Figure 4 Different embodiments of the logistics tower with its grid-layer configuration shown also include vertical retrieval systems. These vertical retrieval systems are typically located above the uppermost material handling storage grid 41 within the logistics tower. As described below, the vertical retrieval system typically includes a lifting system located above each column of vertical lifts included in the logistics tower. The vertical retrieval system typically includes winches, cables, and robotic bin transporters. Overall operation involves raising and lowering the robotic bin transporters to pick up and move storage bins (or “turnaround boxes”) located within the logistics tower storage grid array.

[0027] In the illustrated embodiment, the cell structure of the grid layer uses only multiple first cell groups 39 and second cell groups 49 (e.g., Figure 3A and Figure 3B (As shown and described in the text) Formation. Figure 4 As seen, these two cell groups 39 and 49 can be used to construct a grid-layer storage array, where each grid position is occupied by a functional element, which is either elevator cell 37 or storage cell 31. That is, the grid does not include any unoccupied space. Figure 4 For reference, the subgroup of cell 39 in the first cell group is marked with a gray shading, and the subgroup of cell 49 in the second cell group is marked with a red shading.

[0028] The applicant has recognized the advantages of using a double-depth storage cell configuration to extend the logistics tower, which maximizes efficiency with 100% space utilization. Specifically, the illustrated embodiment employs two cell group elements 39 and 49 (L-shaped and T-shaped), each comprising at least one double-depth storage cell group. For each cell group including a double-depth configuration for at least one pair of storage cells, the scheme can be summarized as follows: The total number of cells in a cell group = 2 × N (N is an integer greater than 1); where Y equals the number of double depths (DD); Formula 1: ; Formula 2: Y = N - 1 For a cell group with a known number of cells, Equation 1 can be used to solve for the integer N, and once N is determined, Equation 2 can be used to find the value Y. For example, to determine the number of double-depth (DD) pairs in a cell group comprising four cells = 4, Equation 1 is solved to determine N = 2. Equation 2 yields the number of 4-cell groups containing one double-depth pair to provide building blocks for constructing the storage cell array, thereby maximizing efficiency by eliminating unoccupied cell positions. As another example, to determine the number of double-depth (DD) pairs in a cell group comprising six cells = 6, Equation 1 is solved to determine N = 3. Equation 2 yields the number of 6-cell groups containing two double-depth pairs to provide building blocks for constructing the storage cell array, thereby maximizing efficiency by eliminating unoccupied cell positions. Regardless of whether it is... Figure 4 Whether it's a smaller storage array or a larger one, the aforementioned scheme also expands by eliminating unused space, thereby maximizing efficiency and increasing storage density for a logistics tower with a selected geometry.

[0029] Figure 4A set of intersecting reference lines included in each cell group also illustrates the horizontal reachability of each elevator cell 37 within each cell group 39, 49. These reference lines show the direct path from the elevator shaft to each storage cell 31, 45, 47A, 47B included in the associated cell group within any cell group 39, 49. A robotic bin transporter operating within the elevator shaft of any cell group 39, 49 directly reaches each single-depth storage cell 31 adjacent to the elevator shaft. For each double-depth cell pair 45, 47A, 47B, a robotic bin transporter in the associated elevator shaft directly reaches each of the storage cells in that pair immediately adjacent to the elevator shaft 37. The robotic bin transporter reaches the distant storage cell via a storage cell positioned between the elevator shaft 37 and a second or distant storage cell.

[0030] Now for reference Figure 5 The illustration depicts a logistics hub 551 comprising a multi-layer storage array 553 according to some embodiments. In various embodiments, the logistics hub 551 employs multiple double-depth cell groups. These double-depth cell groups may include cell groups with a three-compartment double-depth configuration. According to the illustrated embodiment, the logistics hub 551 includes a conveyor grid, a material transfer section 555, and a picking section 559 located below the bottom storage cell array.

[0031] Storage array 553 includes multiple winch-based retrieval systems 561, also known as "in-tower robots." Multiple storage bins 565 are used to store materials in logistics hub 551. The conveyor grid system includes multiple conveyors, such as a first conveyor 567A, a second conveyor 567B, a third conveyor 567C, and others. These conveyors are constructed using individual conveyor blocks laid adjacent to each other on the base of logistics hub 551. In the illustrated embodiment, conveyor 567 is located at the base of the logistics hub, below the multi-level storage array 553. Here, conveyor 567 travels along a first direction from below the multi-level storage array 553 through material transfer section 555 to retrieval section 559, or alternatively, along a second direction opposite to the first direction, to move storage bins from retrieval section 559 or material transfer section 555 to below the storage array 553.

[0032] Now for reference Figure 8The conveyor module may include a standard conveyor module 568 and a right-angle transfer module 569. According to one embodiment, the standard conveyor module 568 includes at least one motor-driven roller combined with a plurality of idler rollers. In operation, the standard conveyor module 568 moves a storage bin along the longitudinal axis of the conveyor in a straight path. The motor can be operated to provide a conveyor module that can reverse direction. The right-angle transfer module 569 includes a set of motorized rollers positioned at right angles to the longitudinal axis of the conveyor when installed in place. The right-angle transfer module 569 includes motorized rollers that operate to change the travel path of the storage bin by 90 degrees. In operation, the right-angle transfer module 569 includes a closed state in which the module allows the storage bin to continue advancing along the longitudinal axis of the conveyor 567 in a straight path. The right-angle transfer module 569 also includes an open state in which the motorized operation of the rollers guides the bin at a right angle from the first conveyor to an adjacent grid located in the second conveyor.

[0033] These motorized conveyor modules 568, 569 provide force to selectively move storage bins 565 located on conveyor module 567 along a first direction or a second direction 180 degrees opposite to the first direction. When placed adjacent to each other in a straight-line alignment, conveyor module 567 moves storage bins 565 directly along the first or second direction. For example, this configuration forms a row of conveyor modules in material transfer section 555, located below the corresponding row in storage array 563 including elevator cells. Transfer modules 569 are used in the conveyor grid to allow bins to change direction of travel. The conveyor grid, composed of individual conveyor modules 568, 569, allows for rapid movement of storage bins 565 while providing precise control over travel, direction, and speed as storage bins move from a first position to a second position in logistics hub 551. For example, the control system can selectively operate transfer conveyor modules 569 to move storage bins between conveyors. In different embodiments, this can be accomplished by controlling the operation of the entire conveyor system piece by piece.

[0034] Typically, the operation of logistics hub 551 allows users to pick up materials at a selected pick-up location within the pick-up area 559. A control system identifies the selected material to be picked up and guides the operation of a winch-based lifting system to retrieve the material from storage array 553 (where materials are stored in bins) and place the bins onto a conveyor included in material transfer section 555. Material transfer section 555 operates to move the bins to the pick-up station.

[0035] Now for reference Figure 6This illustration depicts a logistics hub 651 according to an embodiment, including mobile in-tower robots 661. Each in-tower robot includes a winch system configured to raise and lower a bin transporter. Additionally, each in-tower robot includes a set of wheels and a drive system for powering the wheels, operated by a motor. The logistics hub 651 includes a multi-level storage array 653 and an upper level 677. The multi-level storage array 653 is configured to provide elevator cells arranged vertically to each other, forming a shaft from the upper level 677 to a material transfer layer located at the base of the logistics hub 651. The multi-level storage array 653 also includes storage cells configured to hold storage bins 665. Each in-tower robot 661 communicates with a central control system that transmits data including operating instructions to the in-tower robot 661. The operating instructions provide the information required for the in-tower robot 661 to coordinate its activities within the logistics hub 651 to move the storage bins within the multi-level storage array 653.

[0036] refer to Figure 7 This illustrates a logistics hub 751 including a mobile tower robot 761 according to another embodiment. Figure 7 A top view is provided, showing the structure of the upper layer 777, on which the tower robot 761 moves between positions above different elevator columns included in the multi-level storage array 753. These operations will be described in further detail below.

[0037] Refer again Figure 8 To provide a clearer view of the storage trolley 565, the storage trolley structure includes an edge 579. According to some embodiments described in more detail below, a locking system in a bin transporter, including in-tower robots 551, 661, 761, 1061, and 1161, utilizes the edge 579 to securely grip the storage bin 565, thereby enabling secure gripping within multi-layer storage arrays 553, 653, or as described below. Figure 10 Transport within a vertical storage grid of 1075. According to... Figure 8 In the embodiment shown, edge 579 includes a raised edge that is more easily engaged by a locking mechanism included in the bin transporter.

[0038] refer to Figure 9AThe illustration shows a top view of a model cell group 971 used in a material handling storage grid in a logistics hub, according to various embodiments. The model cell group 971 includes an elevator cell 937 and storage cell groups 931 located on three sides of the elevator cell 937 to form an inverted T-shape. In the illustrated embodiment, each of the three sides includes four storage cell compartments. For example, a first storage cell group 947A is located on the first side of the elevator cell 937, a second storage cell group 947B is located on the second side of the elevator cell 937, and a third storage cell group 947C is located on the third side of the elevator cell.

[0039] The overall configuration of model cell group 971 is referred to as a three-compartment configuration because the elevator cell 937 has access to storage cells on each of the three sides. In the illustrated embodiment, each of the first cell group 947A, the second cell group 947B, and the third cell group 947C includes four storage cells, collectively referred to as a "quad-set." This configuration can be used when the in-tower robot employed with this cell group is configured to extend four compartment depths within the storage grid. Figure 9A The model cell group 971 shown is referred to as a three-compartment quaternary configuration because it includes at least one storage cell on three of the four sides of the elevator cell 937 and includes at least one four-depth storage cell group. Although shown as three quaternary groups, other configurations can be used; for example, each of the three groups 947A, 947B, and 947C can be as described in the reference above. Figure 3A and Figure 3B The double-depth cell pair 45 and double-depth pairs 47A and 47B are shown and described. In different embodiments, other combinations of storage cells may be configured into different groups around a single elevator cell.

[0040] The storage cell group within the cell group is served by robotic bin transporters that rise and fall within the elevator cell. Each bin transporter is part of an in-tower robotic vertical retrieval system that raises and lowers the bin transporter itself. The bin transporters are configured to be vertically aligned within the elevator cell with the storage cells at a selected level, and can extend laterally (e.g., horizontally) from that elevator cell to the desired depth within the adjacent storage cell group to retrieve (or return) the storage trolley to a desired location in the storage array. According to some embodiments, the in-tower robotic retrieval system includes an upper assembly comprising at least one winch and associated cables for raising and lowering the bin transporters within the elevator shaft.

[0041] For reference Figure 3A , Figure 3B and Figure 9A The storage cell groups shown and described, including single-tower robot locations, can be provided in a variety of configurations, including a wide range of different configurations, each with at least one double-depth storage cell pair. These different double-depth configurations can be used in a variety of combinations to maximize storage cell density by significantly reducing or eliminating unoccupied cell locations in multi-layer storage arrays.

[0042] Figure 9B This demonstrates a variety of different combinations and configurations of cells that can be used to create multi-level storage arrays. Model cell group 973 includes multiple cell groups that combine at least one double-depth storage cell group with elevator cells served by an in-tower robot. These model cell groups include: a first three-compartment double-depth configuration 971A, wherein two pairs of double-depth cells are located on opposite sides of an elevator cell; a first double-compartment double-depth configuration 971B, wherein two pairs of double-depth cells are located on adjacent sides of an elevator cell; a second double-compartment double-depth configuration 971C, which includes one pair of double-depth cells and one single-depth cell; a second three-compartment double-depth configuration 971D, wherein two pairs of double-depth cells are located on adjacent sides of an elevator cell, and one single-depth cell is located on a third side; a first four-compartment double-depth configuration 971E, wherein three pairs of double-depth cells are located on three sides of an elevator cell, and one single-depth cell is located on a fourth side; a second four-compartment double-depth configuration 971F, which includes a single pair of double-depth cells and a single-depth cell located on each of the remaining three sides; and a third double-compartment double-depth configuration 971G, which includes two pairs of double-depth cells located on opposite sides of an elevator cell. The first single-compartment double-depth configuration 971H has a single double-depth cell pair; the third and fourth compartment double-depth configuration 971I has two double-depth cell pairs located on opposite sides of the elevator cell and single-depth cells located on the remaining two sides; the fourth and fourth compartment double-depth configuration 971J includes two double-depth cell pairs located on adjacent sides of the elevator cell and single-depth cells located on the remaining two sides; the third and third compartment double-depth configuration 971K includes a single double-depth cell pair and single-depth cells located on the two sides adjacent to the double-depth cell pair; the fourth and third compartment double-depth configuration 971L includes three double-depth cell pairs; the fourth double-compartment double-depth configuration 971M has a single double-depth cell pair and a single-depth cell positioned relative to the double-depth cell; the fifth and fourth compartment double-depth configuration 971N includes four double-depth cell pairs, with one double-depth cell pair positioned on each side of the elevator cell. Figure 9B The remaining model cell group 973 shown does not include any double-depth cell pairs.

[0043] In some embodiments, an array construction design algorithm is used to determine the storage cell array that maximizes efficiency and meets performance requirements. This algorithm may take inputs including a combination of: a) the desired storage density (e.g., storage array capacity / footprint); b) the desired material handling speed (e.g., the maximum transport time between picking up a bin at a storage cell location and delivering it at a pickup station); and c) the total available space given the available array height. These three factors (along with others) can be weighted based on their importance to a particular site and application. For example, where material handling speed is critical, a higher percentage of single-depth cell groups may be used. Conversely, where storage density is critical, a higher percentage of double-depth cell groups may be used. Typically, this approach is used to tailor the selection of different types of cell groups to meet project objectives while eliminating unused space to maximize efficiency and increase the storage density of the logistics tower.

[0044] Now for reference Figure 10 The diagram illustrates the top layer of a multi-layer storage array system 1051 according to various embodiments. System 1051 includes multiple mobile in-tower robots, such as mobile in-tower robot 1061. Each in-tower robot includes a winch system and a bin transporter. Additionally, each in-tower robot includes a set of wheels and a drive system for powering the wheels. System 1051 includes a vertical storage grid 1075 and an upper layer 1077. The vertical storage grid 1075 is configured to provide elevator cells arranged vertically to form a shaft extending from the upper layer to a material transfer layer located at the base of the multi-layer storage array system 1051. The vertical storage grid 1075 also includes storage cells configured to hold storage bins. Each in-tower robot 1061 communicates with a central control system that transmits data including operating instructions to the in-tower robot 1061. The operating instructions provide the information required for the in-tower robot 1061 to coordinate its activities within the multi-layer storage array system 1051 to move storage bins within the storage grid 1075.

[0045] The bin transporter, included in each tower robot, raises or lowers as needed to access bins in adjacent elevator cells where it is operating. When the desired layer is properly aligned within the storage grid 1075, a bracket included in the bin transporter extends into and out of the storage cells to place or remove storage bins from positions within the grid. As described above, cell groups can be provided in various configurations designed to maximize efficiency. According to some embodiments, various cell groups, including double-depth configurations, are included in the storage grid 1075. In these double-depth configurations, the bracket included in the bin transporter can extend through a storage cell immediately adjacent to the elevator cell where the bin transporter is located to access a storage cell separated from the elevator cell by one cell.

[0046] according to Figure 10 In the embodiment shown, the upper layer 1077 of the storage grid 1075 includes panels located at the top of any vertical column that is not an elevator column. According to other embodiments, panels are not included at the upper layer 1077. Instead, the top of the multi-layer storage array system 1051 is an open grid. In various embodiments, the in-tower robot 1061 is a self-contained mobile system capable of horizontal movement on the upper layer 1077 at the top of the storage grid 1075 to position itself above different columns. The ability to dynamically reposition the in-tower robot 1061 can reduce the total number of in-tower robots required in system 1051. The flexibility provided by the self-moving in-tower robot 1061 can be compared with the reference... Figure 3A , Figure 3B , Figure 4 This approach, used in conjunction with the scheme shown and described in Figure 9, provides the most efficient use of space served by an ideal number of in-tower robots. It also supports larger-scale dynamic reconfiguration of the system, which can, for example, include converting elevator columns into storage cell columns, or vice versa, without any permanent adjustments to the positions of the individual in-tower robots 1061.

[0047] Now for reference Figure 11 An isometric view of an in-tower robot 1161 according to one embodiment is provided. According to this embodiment, the in-tower robot 1161 includes a winch system 1120, a bin transporter 1122, a frame 1124, a center plate 1126, and wheel pairs 1128. The winch system 1120 includes a plurality of cable reels 1130, each cable reel having an associated motor 1132 and a linear actuator 1134 to enable the winch system 1120 to travel vertically within the frame 1124. The bin transporter includes a bracket, which is shown and described in detail below.

[0048] In the illustrated embodiment, each of the four cable reels 1130 is connected to a different corner of the bin transporter 1122 via cables wound on the reels. When positioned above the elevator column, the overall operation of the in-tower robot 1161 involves raising and lowering the bin transporter 1122 to transfer storage containers within the multi-level storage array system 1051. As the bin transporter is lowered, the cables advance or "unwind" from each reel at the same rate to maintain the bin transporter in a horizontal orientation. A motor 1132 associated with each reel 1130 rotates the reel in a first rotational direction to advance the cable. Reversing the direction of rotation of the motor raises the bin transporter by retracting the cable and rewinding it onto the reel. In each case, an actuator 1134 operates to cyclically lower and then raise the winch assembly 1120 within the frame 1124 of the in-tower robot 1061. The winch assembly performs this vertical displacement within a limited range of motion to uniformly wind and unwind the cable around the reel.

[0049] According to some embodiments, the bin transporter 1122 includes a sensor package, such as an inertial sensor package, to provide feedback on the pitch and yaw angles of the bin transporter. For example, the sensor package may include one or more accelerometers. The feedback provided by the sensor package is used by the in-tower robot control system to control the operation of the motors as cables are wound / unwound around the reels, keeping the bin transporter level. Motor control can be used to increase or decrease the rate of motor rotation as the cables are wound / unwound. This control can be performed uniformly on all four motors / reels, or independently as needed, to adjust the bin transporter back to level.

[0050] Each tower robot 1061, 1161 includes wheels on each of its four sides. In various embodiments, the framework provided by the upper layer 1077 of the storage grid 1075 provides a rail or track system on which the tower robots 1061, 1161 can move on top of the multi-level storage array system 1051 to position themselves above a desired elevator column. In some embodiments, the rail or track system is an integral part of the storage grid framework. In other embodiments, the rail or track system is a separate hardware system fixed to the storage grid framework. In either embodiment, two pairs of wheels (e.g., wheel pair 1128) located on opposite sides of the tower robot 1161 engage with the rail / track system to drive the tower robot 1161 along the upper layer 1077 from a first position above a first elevator column position to a second position above a second elevator column position. This will be described in more detail below.

[0051] In various embodiments, the multi-layer storage array system 1051 and the in-tower robot 1161 themselves include a number of design features to facilitate the mobility of the in-tower robot 1161. For example, the in-tower robot control system included in the multi-layer storage array system 1051 includes wireless data communication between each in-tower robot and a central controller. Wireless communication allows the system controller to provide instructions to individual in-tower robots to initiate movement along the upper layer 1077 from a first position to a second position. The same communication system is used to provide instructions for operating the bin transporter and associated carrier assembly. For example, the in-tower robot may receive an instruction identifying a first group of cells on a selected layer where a storage bin needs to be accessed. The in-tower robot uses this information to operate to position the bin transporter, thereby moving the storage bin from its current position to a conveyor system located on the material transfer layer of the multi-layer storage array system 1051.

[0052] The upper layer 1077 of the storage grid 1075 includes location tags, which, depending on the embodiment, utilize any of a variety of technologies. According to some embodiments, tags suitable for optical scanning are attached to the storage grid; for example, QR code tags may be used. In this embodiment, the in-tower robot 1161 includes a camera-based system or other optical reader configured to read location data from the QR code as the in-tower robot navigates along the upper layer 1077. According to other embodiments, RFID technology is employed. For example, RFID tags may be located on the upper layer 1077 of the storage grid 1075. In this embodiment, the in-tower robot 1161 includes an RFID reader configured to read the RFID tag to determine the current position of the in-tower robot on the upper layer 1077.

[0053] The mobility of the tower robot 1161 is supported by other features of the entire multi-layer storage array system 1051. One example is a wireless communication system that provides a communication network for bidirectional information and data transfer between the tower robot 1161 and a central controller. Additionally, the tower robot 1161 may include a built-in power supply that allows operation while the tower robot is moving at the top of the storage grid 1075. According to this embodiment, the tower robot 1161 includes a battery with sufficient capacity to power drive motors that operate when the tower robot changes position. This embodiment allows the tower robot to be connected to a wired power source when positioned above the elevator column, but to operate without any external wired connection during the time it moves between positions.

[0054] refer to Figure 12 Additional details about the tower robot 1161 are shown according to different embodiments. Figure 12A partial view is provided, showing three of the four reels 1130A, 1130B, and 1130C included in the winch system 1120, and two of the four cables 1131A and 1131B. A first pulley pair 1128 and a second pulley pair 1129 are shown. A portion of a third pulley pair, located on the side opposite the second pulley pair 1129, is visible; see also a single pulley 1145 in the third pulley pair. Figure 12 A partial view of the bracket 1136 included in the bin transporter 1122 is also provided, showing the portion not obscured by the frame 1124. Two wheel pairs 1128 and 1129 are respectively connected to the first wheel frame 1138 and the second wheel frame 1139. A first drive system 1140 is located on top of the first wheel frame 1138. A second drive system 1141 is located on top of the second wheel frame system 1139. Additionally, the in-tower robot 1161 includes an actuator 1142 and a drive rod 1143. According to the illustrated embodiment, the in-tower robot 1161 is located on a storage grid.

[0055] Cables 1131A and 1131B extend from reels 1130A, 1130B, and 1130C, respectively, to the corners of bin transporter 1122. This configuration allows bin transporter 1122 to be suspended within frame 1124 of in-tower robot 1161 when not in use. These cables are also used to suspend bin transporter 1122 as it is raised and lowered within the elevator column of multi-level storage array 1051.

[0056] Wheel pairs (e.g., first wheel pair 1128 and second wheel pair 1129) are located on each side of the tower robot 1161. The two wheel pairs located on opposite sides of the tower robot 1161 operate together to move the tower robot 1161 along a first horizontal direction and a second horizontal direction opposite to the first horizontal direction. Two additional wheel pairs are located on the remaining opposite sides of the tower robot 1161. These two wheel pairs operate together to move the tower robot 1161 along a third horizontal direction and a fourth horizontal direction opposite to the third horizontal direction. In the illustrated embodiment, each of the third and fourth horizontal directions is perpendicular to both the first and second horizontal directions. This arrangement allows the tower robot 1161 to move along all four axes of the upper layer 1077 of the storage grid.

[0057] Each wheel pair includes a drive system comprising a motor and a drive linkage for connecting the motor to the wheels included in wheel pairs 1128 and 1129. In the illustrated embodiment, a first drive system 1140 is located on a first wheel carrier 1138. A belt, chain, or other linkage connects the rotational output of the drive motor to each wheel included in wheel pair 1128. Similarly, a second drive system 1141 is located on a second wheel carrier 1139. Here, the rotational output of the drive motor is hardware-coupled to each wheel included in wheel pair 1129 via a linkage.

[0058] To allow the in-tower robot 1161 to move freely between the columns of the storage grid, each wheel pair includes a lifting mechanism for raising and lowering each wheel pair. This arrangement allows the wheel pairs to temporarily disengage from the track or guide rail on which the in-tower robot 1161 moves. That is, when the in-tower robot 1161 is in a stationary position on the upper layer 1077 of the storage grid, each wheel pair remains in a lowered position engaged with the guide rail or track. Each wheel carrier is also connected to an actuator via an associated drive rod (e.g., actuator 1142 and drive rod 1143 are connected to the first wheel carrier 1138). In some embodiments, the actuator includes a motor, and the drive rod, for example, uses a worm gear connection to connect the rotational output of the motor to the wheel carrier. According to these embodiments, the actuator operates to raise and lower the wheel pairs by raising and lowering the wheel carrier.

[0059] refer to Figure 12 The tower robot 1161 is shown in its operating state in which the first wheel pair 1128 is in an elevated position, disengaged from the storage grid. The second wheel pair 1129 is in a lowered position, engaged with the storage grid. In this operating state, the third wheel pair (partially visible, as indicated by a single wheel 1127) is also positioned to engage with the storage grid. In this state, the tower robot 1161 can move along the storage grid in either of two directions. The first direction is generally oriented towards... Figure 12 The observer, and the second direction is exactly opposite to the first direction.

[0060] For illustrative purposes, the operation of the tower robot 1161 is described, wherein the tower robot is placed as in... Figure 11The state of movement along the storage grid, generally towards or away from the observer, during observation. The tower robot 1161 begins in a stationary state above the first elevator column, with the bin transporter 1122 fully pulled into the frame 1124. In this state, all four wheel pairs (including the first wheel pair 1128 and the second wheel pair 1129) are in a lowered position engaged with the storage grid. The tower robot 1161 begins a positional change, moving the first wheel pair 1128 and the wheel pair positioned opposite it to the first wheel pair to an elevated position where these two wheel pairs are no longer in contact with the storage grid. For the first wheel pair 1128, this positional change is achieved by operating actuator 1142 to move the entire wheel frame 1138 upward. A similar operation occurs for the wheel pair located on the opposite side of the tower robot 1161 via another actuator and drive rod combination located on that side.

[0061] With the two wheel pairs disengaged from the storage grid, the individual drive systems associated with these two wheel pairs operate to rotate the wheels and move the tower robot 1161 in the desired direction. Referring to the second wheel pair 1129, drive system 1140 operates by engaging a motor-driven linkage to convert the motor's operation into rotation of the first wheel pair 1129. A similar operation occurs for the third wheel pair 1127 located on the opposite side of the tower robot 1161 via another drive system on that side. The tower robot 1161 moves along the upper layer 1077 of the storage grid until it reaches the desired position above the second elevator column. At this point, both drive systems shut down. Actuators operate to lower the wheel frame of the first wheel pair 1128 and the attached wheel pair and the wheel pair positioned opposite to the first wheel pair to a lowered position in contact with the storage grid. The tower robot 1161 is now in place to operate the winch system 1120 as needed to reach the bins in the storage cells adjacent to the second elevator column at any level of the multi-level storage array 1051.

[0062] In various embodiments, the upper layer 1077 of the storage grid includes a set of tracks configured such that the wheels of the in-tower robot 1161 travel on them as it moves between various locations on top of the storage grid. The tracks are also laid out in a grid pattern with intersections at fixed intervals to allow the in-tower robot 1161 to travel in any of a plurality of directions. A control system provides navigation instructions that allow the in-tower robot 1161 to travel between two known locations on the tracks without colliding with any other in-tower robot. According to one embodiment, the tracks are formed as an integral part of the structural elements of the upper layer 1077 of the storage grid.

[0063] According to various embodiments, the tower robot 1161 includes a self-contained power system comprising a rechargeable battery to provide power at least to a drive system (e.g., one or more motors and associated mechanical connections to wheels) that operates the wheels as the tower robot moves between various locations on top of the storage grid. These self-powered embodiments allow the tower robot 1161 to move between locations without maintaining a connection to an external power source while the tower robot is transported between locations. According to some embodiments, the tower robot includes contact blocks attached to a frame 1124. The contact blocks are connected to the rechargeable battery. Corresponding stationary contact blocks are located on the storage grid. The contact blocks on the storage grid are connected to a power source for recharging the battery included in the tower robot 1161. In these embodiments, the two contact blocks establish an electrical connection when, for example, the tower robot 1161 is positioned above the elevator shaft. This provides the tower robot 1161 with an opportunity to recharge whenever it is positioned above the elevator shaft. According to another embodiment, the self-contained power system also has sufficient capacity to operate the winch system and hopper transporter in addition to the wheel motor drive system, without requiring a fixed power supply connected to the outside of the robot inside the tower.

[0064] Now for reference Figure 13A bin transporter 1112 is shown according to one embodiment. The bin transporter 1112 includes a base 1152, a first extension 1153, a second extension 1154, and a bracket 1156. The base 1152 includes a coupling 1155. The bracket 1156 includes a frame having a first guide rail 1150A and a second guide rail 1150B located on a side of the frame opposite to the first guide rail 1150A. A first set of rollers 1159A is included on the first guide rail 1150A, and a second set of rollers 1159B is included on the second guide rail 1150B. A locking system is attached to the frame of the bracket 1156. The locking system includes a first locking lever 1165, a second locking lever 1166, a first locking motor 1158A, and a second locking motor 1158B. Locking levers 1165 and 1166 extend perpendicularly to the first guide rail 1150 and the second guide rail 1150B across opposite sides of the bracket 1156 below it. Each end of the locking levers 1165 and 1166 is attached to the guide rails 1150A and 1150B. According to the illustrated embodiment, a first locking motor 1158A is located below the central portion of the first guide rail 1150A. A second locking motor 1158B is located below the central portion of the second guide rail 1150B. The bracket 1156 also includes a pair of guide rails 1167 located on the top side of the frame of the bracket 1156. A pair of extensions 1153 and 1154 include a drive motor 1162, a first pair of drive belts 1163, and a second pair of drive belts 1164. The first extension 1153 is attached in a manner movably engaged with the base 1152. The second extension 1154 is attached in a manner movably engaged with the first extension 1153. The bracket 1156 is attached in a manner that allows it to movably engage with the second extension 1154.

[0065] The first extension 1153 includes a pair of upper and lower guide rails 1168. According to the illustrated embodiment, the pair of guide rails 1168 are formed as part of the frame of the second extension 1153. In different embodiments, when the bin transporter 1122 is located within the tower robot 1161 and when it moves up and down within the elevator cell, the first extension 1153, the second extension 1154, and the bracket 1156 are nested together below the base 1152. The bracket 1156 and the second extension 1154 are attached to each other at a pair of guide rails 1167 disposed on the bracket. The second extension 1154 is attached to the first extension 1152 at the lower guide rail included in the pair of upper and lower guide rails 1168. The first extension 1153 is attached to the base 1152 at the upper guide rail included in the pair of upper and lower guide rails 1168.

[0066] Figure 13 A bin transporter 1122 configured for operation in a storage array comprising pairs of dual-depth storage cells is shown. Although the storage grid 1075 is not in... Figure 13The bin transporter is shown in the diagram, but is depicted in a fully extended position, an operation that can occur within the elevator column of the multi-level storage array system 1051. That is, the winch system 1120 of the tower robot 1161, already operated, lowers the bin transporter below the tower robot's frame 1124, to a selected height within the storage array. From that position, the bin transporter can be operated to extend the first extension 1153 and the second extension 1154 from the base, thereby moving the carrier 1156 into a first storage cell adjacent to the elevator column where the base 1152 is located. The bin transporter 1152 can also be operated to further extend the first extension 1153 and the second extension 1154, thereby moving the carrier 1156 into a second storage cell located on the opposite side of the first storage cell from the base (i.e., positioning the carrier 1156 within a double-depth cell in a double-depth cell pair).

[0067] The drive system for extending the bin transporter 1122 includes a drive motor 1162, a first drive belt 1162, and a second drive belt 1164. According to one embodiment, the first pair of drive belts 1163 includes a series of teeth configured to engage corresponding sets of teeth located on the underside of the base 1152. The second pair of drive belts 1164 includes a series of teeth configured to engage corresponding sets of teeth located on the underside of the first extension 1153. In the illustrated embodiment, a single drive motor 1162 operates to rotate the first pair of drive belts 1163 about the front and rear axles of the first extension 1153, while simultaneously rotating the second pair of drive belts 1164 about the front and rear axles of the second extension 1154. As the drive belts 1163 rotate under the force of the drive motor, the engagement between the sets of teeth provides mechanical force to extend the first extension from below the base 1152. As the drive belt 1164 rotates under the force of the drive motor, the engagement between the gear sets provides mechanical force to simultaneously extend the second extension from below the first extension 1153. When the bracket 1154 extends into the first storage cell of the double-depth cell pair, the first set of rollers 1159A and the second set of rollers 1159B engage on a track included in the storage array 1075. This feature helps the bracket maintain a horizontal position within the storage cell, even under load on the storage bin. To reach the second cell in the double-depth cell pair, the drive motor 1162 further operates to rotate both pairs of drive belts 1163, 1164. This causes both the first extension 1163 and the second extension 1164 to move further horizontally in a distal direction, for example, to a fully extended position. In an alternative embodiment, the two pairs of drive belts 1163, 1164 are driven independently of each other, such that the two extensions 1153, 1154 extend sequentially, one after the other.

[0068] Once the bracket extends into the storage cell, the bin transporter operates the locking system included in the bracket 1156. Typically, locking levers 1165, 1166 grip the opposite edges of the storage bin to secure it to the bracket for transport within the multi-level storage array system 1051 by the in-tower robot 1161. When the bracket 1156 extends above any storage cell within a single-compartment or double-depth storage cell pair, the locking levers 1165, 1166 are positioned above and adjacent to the opposite edges of the storage bin within that cell. Operation of the two locking motors 1158A, 1158B moves the associated locking levers 1165, 1166 respectively, firmly engaging them with the two opposite edges of the storage bin. With the storage bin securely held by the bracket 1156, the storage bin can be pulled into the elevator cell along with the first extension 1153, the second extension 1154, and the bracket 1156 nested together below the base 1152. At this time, the tower robot 1161 operates to raise or lower the bin transporter 1122, which includes the storage bin, to a position where the storage bin is transferred to the material transfer system at the base of the multi-layer storage array system 1051, or alternatively, to remain in another storage cell location accessible from the elevator column where the bin transporter 1122 is located.

[0069] In various embodiments, the bin transporter 1122 rotates 360 degrees about its vertical axis. This allows the bracket 1156 to extend into a storage cell on any of the four sides of the elevator cell where the bin transporter is located. (See reference...) Figure 14 The image shows a view of a bin transport assembly 1180. The bin transport assembly 1180 includes a bin transporter 1122 and a trolley 1170, with the bin transporter 1122 located beneath the trolley. The trolley 1170 includes a frame 1171 and four wheel assemblies 1172A, 1172B, 1172C, and 1172D, with one wheel assembly positioned at each corner of the frame 1170. The trolley 1170 also houses a rotary drive assembly 1176.

[0070] Each wheel assembly 1172 includes a vertical frame 1173 and a wheel pair including a first wheel 1174A and a second wheel 1174B. According to the illustrated embodiment, wheels 1174A and 1174B are positioned in a vertical orientation in which they can engage the vertical frame of the storage array 1075 as the bin transport assembly 1180 moves up and down along the elevator column in the array. In this orientation, the wheels allow the bin transport assembly 1180 to move smoothly vertically from a centrally located fixed position within the elevator column.

[0071] According to some embodiments, the rotary drive assembly 1176 is configured to be attached to Figure 13The connecting element 1155 is shown in the figure. The rotary drive system 1176 includes a motor that operates to rotate the bin transporter 1122 360 degrees about the vertical axis of the bin transporter assembly 1180 below the trolley 1170.

[0072] While the above embodiments relate to a material exchange layer employing a conveyor system, other embodiments may include a shuttle system located in that layer. In these embodiments, the horizontal shuttle system is situated below the vertical storage cell column. According to one embodiment, the horizontal shuttle system includes a horizontal shuttle grid and one or more robotic flatbed shuttles. The shuttle grid is formed by a network of guide rails, or configured as multiple guide rail blocks arranged in a grid pattern or positioned adjacent to each other. The guide rails include grooves that define tracks for the wheels of the robotic flatbed shuttles to traverse. The robotic flatbed shuttles travel along the horizontal shuttle grid to receive storage bins and / or deliver storage bins to one of the robotic bin transporters.

[0073] The aforementioned in-tower robot moves between locations along the upper layer 1077 of the multi-layer storage array system 1051 without a load. That is, it does not carry storage bins. However, in an alternative embodiment, the in-tower robot has sufficient clearance to pull bins into the in-tower robot frame and then move between locations along the upper layer 1077.

[0074] Now for reference Figure 15 A plan view of a multi-layer storage array system 1581 according to some embodiments is shown. In the illustrated embodiment, system 1581 includes a frame 1582, a material transfer system 1583, and multiple mobile tower robots, such as mobile tower robot 1561. Frame 1582 includes vertical members 1584 and horizontal members 1585, which are fastened together to form a three-dimensional storage array including storage cells 1547 and elevator cells 1537. Here, a single elevator cell defined between dashed lines in the three-dimensional region is uniquely identified as elevator cell 1537. However, elevator cells 1537 are vertically positioned relative to each other to define a vertical elevator shaft 1586 within the entire multi-layer storage array system 1581. The overall outline of an elevator cell 1537 located within the storage array system 1581 is shown in dashed lines for reference. The multi-layer storage array system 1581 includes a plurality of storage bins 1565 for temporarily storing materials in bins 1565 accessible via an in-tower robot. A single storage bin 1588 included in the plurality of storage bins 1565 is... Figure 15 The mobile tower robot 1561 is fixed.

[0075] In the illustrated embodiment, the material transfer system 1583 is located below the cells included in the storage array system 1581. In different embodiments, the material transfer system 1583 includes a transport system configured to move storage bins: from an unloading station to a location below multiple shafts; and from the location below the multiple shafts to a retrieval station to store and retrieve material from individual storage bins. The transport system can also move storage bins from a location in a first elevator shaft (where the storage bin is retrieved and unloaded (after being removed from a first storage cell)) to a location in a second elevator shaft (where the storage bin is raised back into the storage array and placed into a different storage cell). For example, if the storage bins contain material selected for retrieval less frequently than expected, the storage bins can be moved to a more remote location in the storage array, and vice versa.

[0076] Depending on the embodiment, the material transfer system 1583 may include one or more conveyor systems or shuttle systems, such as mesh robots. In each embodiment, the material transfer system 1583 operates to move storage bins 1565 horizontally below a storage array. In some embodiments, the material transfer system 1583 is configured to move storage bins up and down along ramps included in the system 1583. According to one embodiment, the material transfer system includes a combination of a conveyor system and a shuttle system. When employing a shuttle system, the shuttle system may include a shuttle mesh and one or more robotic flatbed shuttles. The shuttle mesh may be formed by a network of guide rails or configured as multiple guide rail blocks arranged in a grid or positioned adjacent to each other. The guide rails include tracks for the wheels of the robotic flatbed shuttles to travel on. Each mobile tower robot 1561 includes, for example, a plurality of wheels 1528 located on at least two opposite sides of the tower robot 1561. In one embodiment, the plurality of wheels 1528 are included on all four sides of the tower robot 1561. In another embodiment, the multiple wheels can be positioned above the lowest portion of the in-tower robot frame when not in use. In different embodiments, during the repositioning of the mobile in-tower robot 1561 from a first position on top of the storage cell array to a second position on top of the storage cell array, the multiple wheels 1528 are positioned at a height below the lowest height of the in-tower robot frame to allow the in-tower robot frame to leave the frame 1582 during in-tower robot transport. Each mobile in-tower robot 1561 also includes a motor-operated drive system for powering the multiple wheels 1528 to move the in-tower robot between different positions on top of the storage array. For example, moving the in-tower robot 1561 from a first position above a first elevator shaft included in a plurality of elevator shafts to a second position above a second elevator shaft included in a plurality of elevator shafts, the first elevator shaft being a different elevator shaft from the second elevator shaft.

[0077] According to some embodiments, a lifting system is included in the tower robot 1561 (e.g., reference 1561). Figure 11 The winch system 1120 shown and described is configured to move the bin transport assembly vertically up and down within the lift shaft to align the bin transport with a first storage cell group located adjacent to the lift shaft. With the bin transport positioned adjacent to the first storage cell group, the bin transport is configured to operate to retrieve the storage bin and move the first storage bin vertically within the first lift shaft to lower the first storage bin into a transport system included in the material transfer system 1583 and release the storage bin into the transport system for horizontal transport. According to these embodiments, an in-tower robot 1561 is configured to move from a first position above the first lift shaft to a second position above the second lift shaft on top of the storage array, and then move the bin transport assembly vertically within the second lift shaft to align the bin transport with a second storage cell group located adjacent to the second lift shaft to retrieve the second storage bin and deliver the second storage bin to the transport system.

[0078] As described in more detail above with reference to the foregoing figures, each mobile tower robot 1561 may include a winch system and a bin transporter assembly. The bin transporter raises or lowers as needed to access bins in adjacent elevator cells in which it is operating. Similarly, each mobile tower robot 1561 communicates with a central control system that transmits data including operating instructions to the mobile tower robot 1561. The operating instructions provide the mobile tower robot 1561 with the information required to coordinate its activities within the multi-layer storage array system 1581 to move storage bins 1565 within the storage grid.

[0079] According to the illustrated embodiment, a bin handling assembly is included in the mobile tower robot 1561 (see reference). Figure 14 The bin handling assembly 1180 shown and described is in its uppermost position. That is, the winch system has raised the bin handling assembly as high as possible within the frame of the mobile tower robot 1561. As described elsewhere herein, the bin handling assembly, including the trolley and bin handling mechanism, is located within the frame of the mobile tower robots 1161, 1561 when raised to its uppermost position. That is, these components are completely retracted into the tower robot frame (see, for example, see...). Figure 11 (and frame 1124). This allows the mobile tower robots 1161, 1561 to reposition between different locations on top of the storage array, because the frames of the tower robots 1161, 1561 are raised above the upper layer (e.g., upper layer 1077) of the storage array on which the mobile tower robots 1161, 1561 travel. Figure 15 As shown, the bottom of each of the multiple wheels 1528 is lower than the lowest part of the frame. This is used to raise the frame of the mobile tower robot to provide the clearance required for the tower robot to travel on top of the storage array.

[0080] However, in these embodiments, at least the lower portion of the bin 1588 is positioned below the frame and below the bottom of each of the plurality of wheels 1528. Therefore, in these embodiments, the mobile tower robot 1561 cannot move laterally on top of the storage array while holding the bin (even when the bin handling assembly is in a fully raised position) because the bin 1588 would collide with the frame 1582.

[0081] The applicant discovered that the aforementioned limitations can be addressed for positional subgroups within the multi-level storage array system 1581 by establishing "high-speed travel channels." These high-speed channels eliminate certain horizontal elements included in adjacent cell groups at or near the top of the frame 1582 to provide areas for linear (straight-line) travel between different elevator cells. According to these embodiments, eliminating selected horizontal elements provides travel paths that do not interfere with the movement of in-tower robots 1161, 1561 holding bins (e.g., bin 1588). In practice, this approach can be used in areas of the multi-level storage array system 1581 where the storage cells with the greatest bin handling or movement are located.

[0082] Although the foregoing reference to the bin handling machine (including movement into both inner and outer storage cells to retrieve the bin's extension) illustrates and describes bin (or tote) retrieval, other methods may be used according to other embodiments. For example, the bin handling machine may alternatively be coupled to the side of the elevator cell adjacent to the storage bin via a suitable mechanical interface. In one embodiment, a suction cup attachment is employed. In another embodiment, the bin handling machine includes hardware for latching to the proximal sidewall of the bin without extending into the storage cell.

[0083] Thus far, several aspects of at least one embodiment of the present invention have been described. It should be understood that various changes, modifications, and improvements will readily occur to those skilled in the art. Such changes, modifications, and improvements are intended to be part of this disclosure and are intended to fall within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are merely illustrative.

[0084] Claims.

Claims

1. A storage system, comprising: A three-dimensional structure, comprising: A cell array comprising: a first plurality of cells configured to maintain independent storage bins for retrieval, the cell array forming a plurality of storage layers located at different heights within the three-dimensional structure; and a second plurality of cells positioned relative to each other to form a plurality of shafts within the three-dimensional structure, the plurality of shafts configured to allow access to storage cells included in the first plurality of cells located in each of the plurality of storage layers; and A material transfer layer located below the plurality of storage layers includes a transport system configured to move the individual storage bins in such a way as to: a) move them from the unloading station to locations below the plurality of shafts; and b) move them from these locations below the plurality of shafts to a picking station; and A plurality of tower robots are located atop the three-dimensional structure. Each of the tower robots includes a vertical lifting system comprising a bin transporter. The tower robots are configured to move the bin transporter vertically within a plurality of shafts to align the bin transporter with a plurality of cells located at different heights. Each of the tower robots is configured to move laterally between a plurality of different positions atop the three-dimensional structure, the plurality of different positions including at least a first position above a first shaft included in the plurality of shafts and a second position above a second shaft included in the plurality of shafts. With the robot positioned in the first location within the tower, the vertical lifting system is configured to position the bin transporter within the first shaft adjacent to a first group of storage cells located at a selected height among these different heights. This first group of storage cells includes at least one inner cell configured to maintain an independent storage bin for later retrieval. The at least one inner cell includes a first side and a second side opposite the first side, the first side being adjacent to the lifting cell where the bin transporter is located at the selected height. Wherein, when the bin transporter is positioned adjacent to the first storage cell group, the bin transporter is configured to extract the first storage bin located in the at least one inner cell for vertical transport from the selected height to the material transfer layer, so that the bin transporter can release the first storage bin into the transport system, thereby allowing the first storage bin to move from a position below the first shaft, and The robot inside the tower is configured to move from the first position to the second position on top of the three-dimensional structure to enter the second shaft, in order to retrieve the second storage bin and deliver the second storage bin to the transport system.

2. The storage system as claimed in claim 1, wherein, The transportation system includes a conveyor system.

3. The storage system as claimed in claim 2, wherein, The conveyor system comprises multiple motorized conveyor modules.

4. The storage system as claimed in claim 1, wherein, These unloading stations and these picking stations are located in the same locations as each other.

5. The storage system as claimed in claim 1, wherein, Each of the multiple tower robots is configured to raise and lower the associated bin transporter between a fully raised position and a fully lowered position. Each of the plurality of tower robots includes a plurality of wheels configured to engage the three-dimensional structure and propel the respective tower robot between multiple different positions on top of the three-dimensional structure. When the associated bin transporter is in the fully raised position and the associated bin transporter is firmly gripping the storage bin, the lower portion of the storage bin extends under the multiple wheels of the corresponding tower robot.

6. The storage system as claimed in claim 5, wherein, Each of the plurality of tower robots includes a winch assembly comprising a plurality of winches, each of the plurality of winches including a cable reel comprising a cable connected to the associated bin transporter, and Each of the plurality of tower robots includes an actuator to automatically raise and lower the winch assembly as the associated bin transporter moves between the fully lowered position and the fully raised position, thereby facilitating the winding of the cable onto the cable reel.

7. The storage system as claimed in claim 1, wherein, The transport system includes a shuttle system configured to move these individual storage bins on the material transfer layer.

8. The storage system of claim 7, wherein, The shuttle system includes a horizontal shuttle grid and one or more robotic flatbed shuttles configured to travel along the horizontal shuttle grid to receive individual storage bins from the bin transporter.

9. The storage system as claimed in claim 1, wherein, The three-dimensional structure further includes a frame having vertical members defining the plurality of shafts, and The bin transporter is included in a bin transporter assembly, which includes the bin transporter and a trolley. The bin transporter is connected to the bin transporter assembly from below the trolley.

10. The storage system of claim 9, wherein, The trolley includes multiple guide wheel assemblies configured to engage with the vertical members of the selected shaft when the bin transport assembly is lowered within the selected shaft.

11. The storage system of claim 1, wherein, The storage cell group includes at least one double-depth storage cell group, which includes at least one inner cell and one outer cell. This includes positioning the outer cell in the at least one double-depth storage cell group on the second side adjacent to the at least one inner cell, and When the bin transporter is positioned adjacent to the storage cell group, the bin transporter is configured to extract the storage bin located in the outer cell for transport from the selected height along the vertical direction to the material transfer layer.

12. The storage system of claim 11, wherein, The at least one inner cell is one of a plurality of inner cells included in the stored cell group. Here, the outer cell is one of a plurality of outer cells included in the stored cell group, and The storage cell group includes multiple double-depth storage cell groups, each of which includes: a) one of the multiple inner cells, each inner cell having a corresponding first side and a corresponding second side opposite to the corresponding first side, the corresponding first side being adjacent to the elevator cell where the hopper transporter is located at the selected height; and b) one of the multiple outer cells, each outer cell being positioned adjacent to the corresponding second side of the corresponding inner cell included in the corresponding double-depth storage cell group.

13. The storage system of claim 11, wherein, The bin transporter includes a base and multiple nested extensions, and These extensions are coupled to at least one motor for moving the extensions between a retracted position below the base and a plurality of extended positions, including a first extended position and a second extended position, in which the bin transporter is positioned to securely grip a first storage bin located in the at least one inner cell, and in the second extended position, the bin transporter is positioned to extend through the empty at least one inner cell to reach the outer cell and securely grip a second storage bin located in the outer cell.

14. A method for storing and retrieving materials, the method comprising: Multiple storage cells are provided, which are arranged together at different heights within a three-dimensional structure, and are configured to maintain independent storage bins for retrieval. It includes multiple elevator cells, which are positioned relative to each other to form multiple shafts within the three-dimensional structure, which are configured to allow access to storage cells located at each of these different heights, which are included in the multiple storage cells. The material transfer layer is positioned below the plurality of storage cells and the plurality of elevator cells. The material transfer layer includes a transport system configured to move the individual storage bins in such a way as to: a) move them from the unloading station to a location below the plurality of shafts; and b) move them from these locations below the plurality of shafts to a retrieval station to store and retrieve materials from the individual storage bins. Multiple tower robots are positioned on top of the three-dimensional structure. Each of the multiple tower robots includes a vertical lifting system, which includes a bin transporter. The multiple tower robots are configured to move the bin transporter vertically within the multiple shafts to align the bin transporter with the multiple storage cells located at these different heights. Each of the multiple tower robots is configured to move laterally on top of the three-dimensional structure between multiple different positions, including at least a first position above a first shaft included in the multiple shafts and a second position above a second shaft included in the multiple shafts. The vertical lifting system is configured to position the bin transporter in the first shaft adjacent to a first storage cell group located at a selected height among these different heights, such that when the bin transporter is positioned adjacent to the first storage cell group, the bin transporter is positioned to extract a first storage bin located in the first storage cell group for vertical transport from the selected height to the material transfer layer, so that the bin transporter can release the first storage bin into the transport system, thereby allowing the first storage bin to move from a position below the first shaft; as well as The robot inside the tower is configured to move from the first position to the second position on top of the three-dimensional structure to enter the second shaft, in order to retrieve the second storage bin and deliver the second storage bin to the transport system.

15. The material storage and retrieval method as described in claim 14, further comprising: The transportation system includes a conveyor system comprising multiple motorized conveyor modules.

16. The material storage and retrieval method as described in claim 14, further comprising: The system includes a shuttle system configured to move these individual storage bins on a material transfer layer in the transport system. The shuttle system includes multiple shuttles configured to travel along a horizontal shuttle grid to receive these individual storage bins from the bin transporter.

17. A tower robot for a storage array comprising a plurality of elevator shafts located above a transport system, the tower robot comprising: frame; A lifting system, which is fixed to the frame; A bin transporter assembly is connected to the vertical lifting system. The bin transporter assembly includes a trolley and a bin transporter, with the bin transporter connected to the bin transporter assembly below the trolley. A wheel assembly that extends below the frame; as well as A drive system configured to rotate the wheel assembly to move the robot within the tower from a first position above a first elevator shaft (one of a plurality of elevator shafts) to a second position above a second elevator shaft (another of a plurality of elevator shafts). The lifting system is configured to move the bin transport assembly vertically within the first lifting shaft to align the bin transport with a first storage cell group located adjacent to the first lifting shaft. Specifically, when the bin transporter is positioned near the first storage cell group, the bin transporter is configured to operate to extract the first storage bin and move the first storage bin vertically within the first elevator shaft, thereby lowering the first storage bin into the transport system and releasing the first storage bin into the transport system for horizontal transport. The robot inside the tower is configured to move from the first position to the second position on top of the storage array, and then move the bin transporter assembly vertically within the second elevator shaft to align the bin transporter with a second storage cell group located adjacent to the second elevator shaft, so as to extract the second storage bin and deliver the second storage bin to the transport system.

18. The tower robot as claimed in claim 17, wherein, When the bin transporter is positioned within a selected elevator shaft, adjacent to a selected group of storage cells at a selected height within the storage array, the bin transporter is configured to extend laterally within the storage array to a storage cell included in the selected group of storage cells to retrieve the selected storage bin; The selected storage bin is retracted and moved into the selected elevator shaft, which is included in the plurality of elevator shafts; The selected storage bin is lowered into the transport system and then released into the transport system for horizontal transport.

19. The tower robot as described in claim 18, wherein, The selected storage cell group includes at least one inner cell configured to maintain an independent storage bin for later retrieval. The at least one inner cell includes a first side and a second side opposite the first side, the first side being adjacent to the elevator cell where the bin transporter is located at the selected height. The selected storage cell group includes at least one double-depth storage cell group, which includes at least one inner cell and one outer cell. This includes positioning the outer cell in the at least one double-depth storage cell group on the second side adjacent to the at least one inner cell, and Wherein, when the bin transporter is positioned near the selected storage cell group, the bin transporter is configured to extract the storage bin located in the outer cell for transporting it vertically from the selected height to the transport system.

20. The tower robot as described in claim 18, wherein, The robot inside the tower includes a vertical axis, and the bin transporter includes a rotary drive system coupled to the bin transporter, the rotary drive system being configured to cause the bin transporter to rotate 360 ​​degrees about the vertical axis below the trolley within the plurality of elevator shafts.

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