Automated storage and retrieval system with modular shipping area and method of construction

Abstract

Systems and methods are provided that may involve a shipping area at an automated storage and retrieval system. In one form, the system may include a storage structure including a storage location and a pathway to be traversed by the mobile robot to access the storage location. The system may also include a shipping area abutting the storage structure and providing access to the mobile robot. The shipping area may include a frame portion formed of beams for coupling to a storage structure and a floor supported by the frame portion. The floor may include a panel having at least one panel that may include a guide line at a predetermined location to facilitate movement of the mobile robot thereon. A panel and a method of construction are also provided.

Description

[0001] Cross Reference to Related Applications This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 472,885, filed June 14, 2023, which is incorporated by reference herein in its entirety. TECHNICAL FIELD

[0002] The present disclosure relates generally to an automated storage and retrieval system for storing goods, and more particularly, to a modular transport area for navigation and movement of mobile robots. BACKGROUND

[0003] Automated storage and retrieval systems (ASRS) are increasingly used in environments where orders for goods are fulfilled. In some forms, these systems can include mobile robots that move about a storage structure at an order fulfillment facility to pick up and transfer containers and items. These containers and items can be stored in storage locations and can need to be transferred to other areas where orders are assembled. In some forms, mobile robots can travel along aisles to access storage locations.

[0004] There is a need for areas where mobile robots can navigate and have access to different aisles. In-rack transport planes (IRTPs) or transport areas or support platforms can be desirable to allow mobile robots to access different aisles and different areas of a storage structure and facility. It would be desirable to provide manufacturing and assembly of support platforms with modular and configurable pre-fabricated panels that can support and help guide robots. BRIEF DESCRIPTION OF DRAWINGS

[0005] Embodiments of systems, devices, and methods related to transport areas and panels, such as those that can be used at an automated storage and retrieval system, are disclosed herein. The specification includes drawings, wherein: Figure 1 is a perspective view of an automated storage and retrieval system according to some embodiments; Figure 2 is a perspective view of an automated storage and retrieval system according to some embodiments Figure 1 is a partial perspective view of an automated storage and retrieval system of Figure 3 is a partial perspective view of an automated storage and retrieval system of Figure 1 Figure 4 is a partial perspective view of an automated storage and retrieval system of Figure 1 Figure 5 is a perspective view of a transport area according to some embodiments; Figure 6 is a perspective view of a transport area according to some embodiments;​​Figure 5 perspective view of a transport area of the Figure 7 is a perspective view of a transport area of the Figure 5 perspective view of a transport area of the Figure 8 is a perspective view of a transport area of the Figure 5 partial perspective view of a panel at a transport area of the Figure 9 is a top view of a panel according to some embodiments Figure 10 is a schematic view of a panel according to some embodiments Figure 9 Figure 11 is a partial top view of a panel at a transport area of the Figure 12 is a partial perspective view of a panel at a transport area of the Figure 11 Figure 13 is a partial perspective view of a panel at a transport area of the Figure 11 Figure 14 is a flowchart according to some embodiments

[0006] For simplicity and clarity, the elements of the figures can be illustrated in isolation and without necessarily illustrating all the components thereof in detail. For example, the size and / or relative positioning of some of the elements in the figures can be exaggerated relative to other elements to help to improve the understanding of various embodiments of the present application. Furthermore, the elements of some of the figures can be depicted in exaggerated or schematic form to help to improve the understanding of various embodiments of the present application. Certain acts and / or steps can be described or depicted in a particular, chronological sequence, but this should not be understood as necessitating that such acts and / or steps be performed in the order as described or depicted. The terminology used herein has its ordinary technical meaning as is consistent with that used by those skilled in the art, unless otherwise defined herein specifically and / or in specific context. The terminology used herein should not be regarded as limiting. DETAILED DESCRIPTION

[0007] ​​​The following description should not be construed as limiting in nature, but merely as an exemplification of the broad generality of the n principles of the exemplary embodiments. Reference throughout this specification to “a form,” “one embodiment,” “an embodiment,” “some embodiments,” “an implementation,” “some implementations,” “some applications,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Accordingly, appearances of the phrases “in one embodiment,” “in an embodiment,” “in some embodiments,” “in some implementations,” and similar language throughout this specification, but not all embodiments, refer to the particular feature, structure, or characteristic described. However, returning to the description of the figures, the following description is provided, by way of example, to describe the principles of the embodiments.

[0008] The terms “top” and “bottom,” “upper” and “lower,” and “vertical” and “horizontal” can be used herein merely for purposes of example and illustration, and are not intended to limit the description of the embodiments, as the referenced items can be interchanged in position and orientation. Additionally, as used herein, the terms “substantially” and / or “about” mean that the specified dimension or parameter can vary within acceptable manufacturing tolerances for a given application.

[0009] Generally, in accordance with various embodiments, systems, apparatuses, and methods are provided herein for automated storage and retrieval systems. In one form, the system includes a first storage structure including a plurality of storage locations configured to store bins containing cargo, the first storage structure including a first plurality of aisles, each storage location being accessible through an aisle, the aisles being configured to be traversed by a plurality of mobile robots, each mobile robot being configured to access a storage location to deposit or retrieve a bin at the storage location; and a staging area adjoining the first storage structure, the staging area providing access for the mobile robots to at least some of the aisles, the staging area including a frame portion formed by a plurality of beams configured for coupling to the first storage structure, and a floor supported by the frame portion, the floor including a plurality of panels that collectively define the floor, at least one panel including one or more guide lines at predetermined locations of the at least one panel to facilitate movement of a mobile robot thereon.

[0010] In some embodiments, in the system, the one or more guide lines comprise one or more magnetic guide lines, and the at least one panel further comprises at least one recess configured to receive a press-fit metallic material therein to form the one or more magnetic guide lines. In some embodiments, the at least one mobile robot comprises a magnetic sensor to detect the one or more magnetic guide lines to facilitate movement of the at least one mobile robot thereon. In some embodiments, the at least one panel further comprises an alignment feature configured to align the one or more guide lines in a predetermined manner relative to a corresponding accessway configured for entry and exit of a mobile robot between the corresponding accessway and the at least one panel. In some embodiments, the alignment feature comprises at least two mounting holes at predetermined locations of the at least one panel, each configured to receive a fastener therein. In some embodiments, the at least one panel comprises at least one fiducial marker applied to a top surface of the at least one panel, the at least one fiducial marker configured to facilitate determination of position and navigation by a mobile robot. In some embodiments, the at least one panel comprises at least one radio frequency identification (RFID) tag applied to a bottom surface of the at least one panel, the at least one RFID tag configured to facilitate determination of position and navigation by a mobile robot. In some embodiments, the system further comprises a transition plate disposed between one of the at least one panel and a corresponding accessway, the transition plate configured for coupling to the alignment feature of the one panel for aligning the transition plate with the one panel and with the corresponding accessway. In some embodiments, the system further comprises a first plurality of mounting brackets, each mounting bracket coupling a first end of each beam to a corresponding end of the first storage structure. In some embodiments, the system further comprises: a second storage structure comprising a plurality of storage locations configured to store bins containing goods, the second storage structure comprising a second plurality of accessways, each storage location being accessible through an accessway; and a second plurality of mounting brackets, each mounting bracket coupling a second end of each beam to a corresponding end of the second storage structure.

[0011] In another form, there is provided a transport area for an automated storage and retrieval system, the transport area comprising: a frame portion formed of a plurality of beams configured to couple to a first storage structure, the first storage structure comprising a plurality of storage locations configured to store bins containing goods, the first storage structure comprising a first plurality of accessways, each storage location being accessible through an accessway, the accessways being configured to be traversed by a plurality of mobile robots, each mobile robot being configured to access a storage location to deposit or retrieve a bin thereat; and a floor supported by the frame portion, the floor comprising a plurality of panels, at least one panel comprising one or more guide lines to facilitate movement of a mobile robot thereon.

[0012] In another form, a panel for supporting mobile robots traveling thereon is provided, the panel comprising: one or more magnetic guide lines formed in a top surface of the panel at predetermined locations to facilitate movement of the mobile robots along the top surface; at least one recess formed in the top surface of the panel, the at least one recess configured to receive a metallic material therein to form the one or more magnetic guide lines; and an alignment feature configured to align the one or more magnetic guide lines in a predetermined manner relative to a corresponding aisle configured for entry and exit of the mobile robots between the corresponding aisle and the panel. The panel can further include some or all of the other features mentioned above.

[0013] In yet another form, a method of constructing an automated storage and retrieval system is provided, the method comprising: providing a storage structure comprising a plurality of storage locations configured to store bins containing goods, the storage structure comprising a plurality of aisles, each storage location being accessible through an aisle, the aisles being configured to be traversed by a plurality of mobile robots, each mobile robot being configured to access a storage location to deposit or retrieve a bin at the storage location; coupling a frame portion of a transit area to the storage structure by coupling a plurality of beams to the storage structure, the transit area allowing entry or exit of the mobile robots to or from the aisles; and installing a floor supported by the frame portion, the floor being formed from a plurality of panels collectively defining the floor, at least one panel including one or more guide lines at predetermined locations of the at least one panel to facilitate movement of the mobile robots thereon.

[0014] In some embodiments, the method can further include receiving at least one panel pre-formed with at least one recess prior to installation of the floor, the at least one recess receiving a metallic material in compression fit therein to form the one or more guide lines. In some embodiments, the method can further include applying at least one fiducial marker to the at least one panel after installation of the floor, the at least one fiducial marker being configured to facilitate determination of position and navigation by the mobile robots traveling on the floor. In some embodiments, the method can further include applying at least one RFID tag to the at least one panel after installation of the floor, the at least one RFID tag being configured to facilitate determination of position and navigation by the mobile robots traveling on the floor. In some embodiments, the method can further include receiving at least one panel having an alignment feature aligning the one or more guide lines in a predetermined manner relative to a corresponding aisle configured for entry and exit of the mobile robots between the corresponding aisle and the at least one panel. In some embodiments, the alignment feature includes at least two mounting holes at predetermined locations of the at least one panel, the at least two mounting holes each being configured to receive a fastener therein.

[0015] In one aspect, and not limited to, this disclosure is generally aimed at reducing excessive labor and time in the installation of transport areas connected to storage structures. These transport areas can be generally configured for use by mobile robots retrieving bins of goods stored in specific storage locations within adjacent storage structures, which are part of an automated storage and retrieval system. The transport area can allow the robot to access different areas of the automated storage and retrieval system from the storage structures. The robot can utilize various features for navigation and position awareness, which may need to be created within custom construction at considerable cost and risk. Typically, the construction of the transport area can be done on-site and can involve multi-layered installation procedures, introducing multiple opportunities for error. Installation procedures may include building a framework and setting up the floor, followed by the construction of navigation features and columns for maneuvering the robot.

[0016] In one aspect, and not limited to, this disclosure utilizes the manufacture of modular components in a factory environment using prefabricated panels (or tiles) that can be assembled with high efficiency and low risk. Furthermore, this disclosure provides the manufacture of guide lines in the panel surface for robotic transport. Additional features can also be incorporated into the panel surface for robot position sensing. This innovation allows for modular and scalable construction of transport areas, thereby reducing costs and eliminating assembly risks. It also reduces on-site manufacturing workload.

[0017] Figure 1 and Figure 2 A view of an automated storage and retrieval system 100 is shown. In one embodiment, the system 100 may be wholly or partially integrated into an order fulfillment facility. The system 100 may include one or more storage structures 102 having a plurality of storage locations 104. Each storage structure 102 may include a yz array of storage locations in a horizontal row and a level-changing vertical tower. A mobile robot 108 may travel between storage levels in the z-direction within the level-changing tower. The storage structures 102 may form pairs of storage bays 110 arranged facing each other and separated by a passageway 112. In one embodiment, the passageway 112 may be in the form of an aisle, and the aisle 112 may have a width such that the mobile robot 108 traveling within the aisle 112 may transfer containers to (or retrieve containers from) a storage bay 110 on either side of the aisle 112. The general concept is that the mobile robot 108 can transport bins of goods from storage location 104 to a designated area for picking up goods. In some forms, the mobile robot 108 may also carry bins containing goods to be returned to storage structure 102.

[0018] Figure 1 and Figure 2 An example of a transport zone 114 or intra-rack transport plane (IRTP) is shown, which is discussed in more detail below. The transport zone 114 can be positioned at different vertical levels between the storage structures 102. The transport zone 114 can enable the mobile robots 108 to access different aisles of the storage structures 102, access different storage structures, or access other areas of the system or facility.

[0019] As noted above, the automated storage and retrieval system 100 can utilize a plurality of mobile robots 108 to transfer totes or other product or order containers to and from the storage locations 104. The term “tote” broadly refers to any kind of container that can be used to hold goods. The mobile robots 108 can be self-guided and / or track-guided to move horizontally and vertically within the aisles 112 to transfer totes or other product containers between the mobile robots 108 and the storage locations 104. The mobile robots 108 can access storage racks on either side of the aisle 112 in the x-direction on a given level. As set forth, the system 100 can also include vertical level change towers within which the mobile robots 108 can travel vertically in the z-direction between levels of the storage locations 104.

[0020] Additional details of various embodiments of storage structures, mobile robots, and other aspects of automated storage and retrieval systems that can be used are described, for example, in U.S. Patent Nos. 9,139,363; 10,435,241; 11,142,398; 10,984,375; 10,952,533; 11,267,651; U.S. Patent Application No. 63 / 127,762; and U.S. Patent Application No. 17 / 957,266. Each of these patents and applications is incorporated by reference herein in its entirety.

[0021] Figure 3 A portion of the automated storage and retrieval system 100 is shown with some of the storage structures removed for clarity. Figure 3Three transit areas 114 at different vertical levels (i.e., stacks) intermediate and connecting the two storage structures 102A and 102B are shown. As explained further below, each transit area 114 is generally in the form of a floor of a panel supported by a frame of beams. The ends of each transit area 114 are attached to a column 116 at the corresponding end of each storage structure 102A and 102B. In one form, it is contemplated that the mobile robots 108 retrieve totes containing goods from storage locations 104 within each storage structure 102A and 102B. The transit areas 114 allow the mobile robots 108 exiting the aisles 112 from a storage structure 102A to turn and enter a different aisle 112 in the same storage structure 102A to orient themselves and enter a selected aisle 112 in a second storage structure 102B, or travel to a different area within the automated storage and retrieval system 100, such as a designated order pick-up area.

[0022] Figure 4 Another portion of the automated storage and retrieval system 100 is shown, with some of the storage structures removed for clarity. Figure 4 Two transit areas 114 at different vertical levels adjacent a storage structure 102 are shown. One end of each transit area 114 is attached to a column 116 at the corresponding end of the storage structure 102. The other end of each transit area 114 is attached to another column 116. The transit areas 114 allow the mobile robots 108 exiting the aisles 112 from a storage structure 102 to turn and enter a different aisle 112 in the same storage structure 102, or travel to a different area within the automated storage and retrieval system 100, such as a designated order pick-up area.

[0023] Accordingly, in some forms, the automated storage and retrieval system 100 includes one or more storage structures 102 and a plurality of mobile robots 108. In one form, the system 100 can include a first storage structure 102A that includes a plurality of storage locations 104 configured to store bins containing goods. The first storage structure 102A can include a plurality of aisles 112, wherein each storage location 104 is accessible via the aisles 112. The system 100 can also include a plurality of mobile robots 108 configured to traverse the plurality of aisles 112 of the first storage structure 102A. Each mobile robot 108 can be configured to access a storage location 104 to deposit or retrieve a bin at the storage location 104. The system 100 can also include a second storage structure 102B that includes a plurality of storage locations 104 configured to store bins containing goods, wherein the second storage structure 102B includes a plurality of aisles 112, and wherein each storage location 104 is accessible via the aisles 112.

[0024] Referring to Figure 5 , a partially assembled conveyance area 114 is shown. In this figure, only the support end of the storage structure(s) 102 is shown. The conveyance area 114 includes a frame portion 118 and a floor 120. The frame portion 118 includes several beams 122 attached to one or more storage structures 102. In the example shown, the two ends of the beams are attached to corresponding ends of the storage structures 102A and 102B. In other examples, one end of the beams is attached to a corresponding end of the storage structure 102, while the other end of the beams is attached to a column 116. Figure 3 Figure 4

[0025] Figure 6 and Figure 7 shows the assembled conveyance area 114. In one form, the conveyance area 114 can be composed of two types of panels: conveyance panels 124 and connection panels 126. In the figure, in this particular example, there are four conveyance panels 124. Each conveyance panel 124 can include guide lines 128 that extend along two centerlines of each conveyance panel 124, which subdivides each conveyance panel 124 into four sections. These guide lines 128 allow for guided movement of the mobile robots 108 along these centerlines, as explained further below. The connection panels 126 extend in a central strip between the two sets of conveyance panels 124. In this form, the panels 124 and 126 are fastened to one another by cleats 130, as also shown in Figure 8 . These cleats 130 are optional, and in another form, it is envisioned that alternative fasteners can be used. Additionally, as​​Figure 7 As can be seen in FIG. 1, a transition plate 132 can be provided that connects and aligns the aisle 112 in the storage structure 102 with the guide lines 128 of the floor panel 124. The transition plate 132 is described in greater detail below.

[0026] Accordingly, in some forms, the system 100 can include a transport area 114 that adjoins the first storage structure 102A, the transport area 114 providing access for the mobile robots 108 to enter or exit the aisle 112 of the storage structure 102. The transport area 114 can include a frame portion 118 formed of a plurality of beams 122 configured for attachment to the first storage structure 102A. Additionally, the system 100 can include a floor 120 supported by the frame portion 118, where the floor 120 is formed of a plurality of floor panels that collectively define the floor 120. The floor 120 can include at least one floor panel 124 having one or more guide lines 128 at predetermined locations of the floor panel(s) 124 to facilitate movement of the mobile robots 108 thereon.

[0027] Reference Figure 9 A top view of a floor panel 200 is shown in FIG. 2. In one form, it is contemplated that the floor panels 200 having the features described below can be used generally in the transport area 114 and in the automated storage and retrieval system 100. They can be pre-fabricated in whole or in part and used in a modular fashion in the floor of the transport area 114. In another form, it is contemplated that the floor panels 200 can be used in other situations where it is desirable to provide a surface for movement and navigation of mobile robots thereon.

[0028] The floor panel 200 can be generally rectangular in shape and can include two guide lines 202 formed generally along the horizontal and vertical centerlines of the floor panel 200. In such a form, a robot can proceed along one of the centerlines and then either proceed straight or turn at or near the intersection of the two centerlines. Although the guide lines 202 are shown as being formed along the horizontal and vertical centerlines of the floor panel 200, it is contemplated that other forms of guide lines can be used. For example, the guide lines 202 can be disposed at a predetermined non-perpendicular angle relative to the edges of the floor panel. Further, it is contemplated that the guide lines can be in the form of a spaced pattern at predetermined locations on the floor panel 200 that a robot can detect and use for navigation. Other robot guides are also usable.

[0029] In one form, the guide wires 202 can be magnetic and the at least one recess is configured to receive a press-fit metallic material therein to form one or more magnetic guide wires 202. In such a form, the magnetic guide wires 202 can be created by pressing magnetic material into the recesses that are designed to capture the wire in a press-fit without the need for adhesive. It is also contemplated that these magnetic guide wires 202 can be pre-fabricated at a separate location by a panel manufacturer to form the floor 120 of the shipping area 114. In one form, the panels can be partially formed from a resin material.

[0030] Referring to Figure 10 a schematic side view of a panel 200 is shown with a mobile robot 108 traveling above the panel 200. As can be seen, the panel 200 includes magnetic guide wires 202 formed in a top surface of the panel 200. In one form, it is contemplated that the mobile robot 108 can include a magnetic sensor 109 to detect one or more of the magnetic guide wires 202 to facilitate movement of the mobile robot 108 over the panel 200. This magnetic sensor 109 can be a Hall effect sensor and can be disposed at a bottom of the mobile robot 108. In some cases, it can be desirable to use magnetic guide wires 202 instead of painted guide wires. Painted guide wires can tend to wear off under certain conditions, such as for example, when the mobile robot 108 moves in and out of a temperature controlled environment, and can not be sensed by the optical sensors of the mobile robot 108. Under these conditions, the optical sensors used to follow the painted lines can become obscured and inoperable.

[0031] Figure 9 An alignment feature is also shown for aligning the panel 200 in a particular orientation, such as for installation in the shipping area 114. In one form, the panel 200 can include an alignment feature for aligning the magnetic guide wires 202 in a predetermined manner relative to a corresponding aisle 112 that is configured for the mobile robot 108 to exit from the corresponding aisle 112 to the panel 200. This alignment feature can include at least two mounting holes 208 at predetermined locations of the panel 200, where the mounting holes 208 are each configured to receive a fastener therein. As can be seen, in one form, these mounting holes 208 can be disposed near an edge of the panel 200 that corresponds to a longer side of the rectangle. These mounting holes 208 receive fasteners that attach the panel 200 to an underlying beam 122.

[0032] In one aspect, these mounting holes 208 align the magnetic guide lines 202 with the corresponding channel. In other words, in one form, the mounting holes 208 allow the magnetic guide lines 202 of the panel 200 to be precisely aligned with the centerline of the channel of the storage structure 102. Additionally, this alignment feature can be used to facilitate installation and reduce installation errors by allowing the panel 200 to be installed only in a specific orientation. For example, as... Figure 9 As shown, the mounting holes 208 can be arranged such that the panel 200 can be mounted in only one of two orientations, i.e., with the longer side parallel to the end of the storage structure 102. In other words, there can be two sets of mounting holes 208, each set arranged adjacent to the edge of the longer side, which allows the panel 200 to be mounted in one of the two orientations. This mounting hole arrangement is asymmetrical because it does not allow the panel 200 to be mounted in the other two orientations, which reduces installation errors. Alternatively, as another example, the mounting holes 208 may also be arranged such that the panel 200 can be mounted precisely in one orientation. In one form, it is envisioned that these mounting holes 208 can be formed by the panel manufacturer at a separate location before shipment and installation to form the floor 120 of the transport area 114.

[0033] Figure 9 Two sets of fastener holes 210 arranged parallel to each other are also shown. In some forms, it is envisioned that these two sets of fastener holes 210 could be used as an alternative to the connecting piece 130 described above. This pattern of fastener holes 210 allows the panel 200 to be fastened to the beam 122 using standard self-tapping screws. Similarly, in one form, it is envisioned that these fastener holes 210 could be formed by the panel manufacturer before installation.

[0034] Panel 200 may also include features that assist in the navigation of the mobile robot 108. For example, panel 200 may include at least one reference mark 212 applied to the top surface of panel 200. Figure 9 As shown, in one configuration, two reference marks 212 may be present, formed near the center of panel 200. In this configuration, the two reference marks 212 are generally diagonally oriented relative to the horizontal and vertical magnetic guide lines 202. Furthermore, in this configuration, they are located in opposing, facing quadrants of panel 200, as defined by the horizontal and vertical magnetic guide lines 202, and are generally symmetrical about the center. This symmetrical arrangement allows panel 200 to be mounted in one of two orientations (one orientation is 180 degrees relative to the other).

[0035] In one embodiment, it is envisioned that grooves be cut into panel 200 during prefabrication and prior to panel 200 installation. Then, after panel installation, reference marks in the form of reference magnets can be installed in these grooves. In other words, reference marks 212 can be applied or formed after panel 200 installation.

[0036] These reference markers 212 can be used as reference points to allow the mobile robot 108 to determine its position and assist in navigation. Generally, it is envisioned that these reference points can be detected by the imaging sensors of the mobile robot 108. In other words, the reference markers 212 are configured to facilitate position determination and navigation by a mobile robot traversing the floor 120 of the transport area 114. Although an example of the type and arrangement of reference markers is shown, it should be understood that other types and arrangements may also be used.

[0037] Another feature that can be used as a navigation aid is the RFID tag 214. The RFID tag 214 can be used as a supplement to or alternative to the reference tag 212. For example, as... Figure 9 As shown, the top surface of panel 200 includes markings 213 for drilling holes to mount RFID tags 214. These markings may be arranged symmetrically around the center of panel 200 to allow panel 200 to be mounted in one of two orientations. Furthermore, in one form, these markings are applied during the prefabrication of panel 200.

[0038] In addition, such as Figure 10 As can be seen, it is generally envisioned that the RFID tag 214 can be applied to the bottom or underside surface of the panel 200. In one form, a hole is drilled through the panel 200 to allow the RFID tag 214 to be applied to the bottom surface after the panel 200 has been installed. The panel 200 may include at least one RFID tag 214 applied to the bottom surface of the panel 200. The RFID tag 214 is configured to facilitate location determination and navigation by a mobile robot traveling on the floor 120.

[0039] As described above, the automated storage and retrieval system 100 may include a transition plate 132. Figure 11 It is a top view of a portion of the panel 200 connected to the transition plate 132, and Figure 12 This is a partial perspective view of the panel 200 connected to the transition plate 132. In one embodiment, the transition plate 132 is located between the panel 200 and the corresponding aisle 112 of the storage structure 102. In one aspect, the magnetic guide lines 202 of the panel 200 are intended to be aligned with the centerline of the corresponding aisle 112. In one embodiment, it is envisioned that the mobile robot 108 can be self-guided and / or track-guided along the centerline of the aisle 112 of the storage structure 102.

[0040] As can be seen in Figure 11 The transition plate 132 is configured for attachment to the mounting holes 208 of the panels 200 for alignment of the transition plate 132 with both the panels 200 and with the corresponding aisle 112. It includes two protrusions or extensions 133 with through holes to allow mounting and alignment of the transition plate 132 with the mounting holes 208 of the panels 200. In one form, the transition plate 132 allows the mobile robots 108 to traverse across the smooth coplanar surface from the storage structure 102 to the conveyance area 114. It can also act as a transition between the slightly different heights of the panels 200 in the aisle 112 of the storage structure 102 and the conveyance area 114. Further, it shares the same mounting holes 208 with the panels 200, sharing alignment features with the panels 200. Additionally, as can be seen in Figure 11 In one form, it can be mounted between two beams 122 and two uprights 116.

[0041] The automated storage and retrieval system 100 can also include mounting brackets 134. Figure 13 is a partial view showing the mounting brackets 134 connecting the beams 122 to the uprights 116 at one end of the storage structure 102. In one form, each mounting bracket 134 couples a first end of each beam 122 to a corresponding end of the storage structure 102. The mounting brackets 134 can be used at both ends of the beams 122 to attach the beams to a first storage structure 102A at one end and to a second storage structure 102B at the other end. Further, in one form, the beams 122 forming the framework portion 118 are connected to the support structure 102 while the panels 200 forming the floor 120 are connected to the beams 122. The mounting brackets 134 generally allow for the universal use of standardized beams 122 having the same dimensions and features in various conveyance area assemblies. As can be seen, Figure 13 Two types of mounting brackets 134A and 134B are shown that can be used, although other types of brackets can also be used. In one form, the two types of mounting brackets 134A and 134B are mounted to different structures of the uprights 116, which establishes the desired load bearing assembly.

[0042] Figure 14 A process 300 for constructing an automated storage and retrieval system is shown. It is generally contemplated that the process 300 can involve some or all of the components of the automated storage and retrieval system 100 and can involve some or all of the features of the panels 200. The above description of the system 100 and the panels 200 is generally incorporated herein.

[0043] At block 302, a storage structure having storage locations for storing bins containing goods is provided. It is generally contemplated that the storage structure can include a plurality of access ways in the form of aisles, where each storage location is accessible through the aisles. In one form, it is contemplated that the storage structure is constructed prior to the construction of a conveying area adjacent to the storage structure.

[0044] At block 304, a mobile robot configured to traverse the aisles of the storage structure is utilized. The mobile robot is configured to access the storage locations to deposit or retrieve bins at the storage locations. It is generally contemplated that the mobile robot can be provided at any time during the process 300. For example, the mobile robot can be provided after the construction of both the storage structure and the conveying area is complete.

[0045] At block 306, a pre-fabricated panel(s) with magnetic guide wires and having alignment features is received. In one form, it is contemplated that the panel is received with several pre-fabricated features prior to installation of the panel. Prior to installation of the floor, the panel can be pre-formed with at least one recess that receives a compression fit of a metallic material to form one or more magnetic guide wires. The panel can also include alignment features that align the one or more magnetic guide wires in a predetermined manner relative to a corresponding aisle of the panel that the mobile robot is configured to exit from a corresponding access way to. In one form, the alignment features can include mounting holes at predetermined locations of the panel for receiving fasteners that can establish one of two possible orientations of the panel during installation. Another pre-fabricated feature can include fastener holes to receive fasteners for attaching the panel to a support beam. Additionally, the panel can include indicia that indicate the location of through-holes for applying RFID tags after installation. Furthermore, in one form, an additional reference recess can be cut into the top surface of the panel.

[0046] At block 308, a frame portion of the conveying area is attached to the storage structure. In one form, the frame portion can be comprised of support beams. One end of each support beam can be attached to a corresponding end of the storage structure, and more particularly, to a column at the end of the storage structure. The beams can be attached to the storage structure by mounting brackets.

[0047] At block 310, the panel(s) are oriented according to the alignment features. For example, the alignment features can be in the form of mounting holes that allow the panel to be oriented in one of two orientations. Once aligned, the panel can be affixed to the support beam by fasteners. At block 312, a floor of the conveying area comprised of the panels and supported by the frame portion is installed. During installation, the panels can be aligned and affixed one after another to form the floor.

[0048] After installation, it is contemplated that additional features can be applied to the panels. At block 314, after installation, fiducial markers can be applied to the panels. In one form, these fiducial markers are formed by installing magnets in fiducial grooves on the top surface of the panels. After installation of the floor, at least one fiducial marker can be applied to the panels, and the at least one fiducial marker can be configured to facilitate determining position and navigation by a mobile robot traveling on the floor.

[0049] At block 316, after installation, RFID tags can be applied to the panels. More specifically, after installation of the floor, at least one RFID tag can be applied to the panels, and the at least one RFID tag can be configured to facilitate determining position and navigation by a mobile robot traveling on the floor. These RFID tags can be applied to the bottom surface of the panels. In one form, a through hole can be drilled at the location of the marker on the top surface to facilitate application of the RFID tag. These RFID tags can be applied in addition to or in lieu of the fiducial markers.

[0050] At block 318, after installation, transition plate(s) can be aligned and installed between the panels and the aisles. In one form, the transition plates can each include alignment features, such as, for example, a protrusion / extension with mounting holes that align with the mounting holes of the panels. These transition plates allow a mobile robot to travel from the storage structure to the shipping area, and vice versa.

[0051] Those skilled in the art will recognize that a wide variety of other modifications, changes and combinations can also be made to the above-described embodiments without departing from the scope of the present invention, and that such modifications, changes and combinations will be considered to be within the scope of the inventive concept.

Claims

1. An automated storage and retrieval system, comprising: A first storage structure includes a plurality of storage locations configured to store bins containing goods. The first storage structure includes a first plurality of pathways, each storage location being accessible via a pathway. The pathways are configured to be traversed by a plurality of mobile robots, each mobile robot being configured to access a storage location to store or retrieve a bin at the storage location. as well as A transport area, adjacent to the first storage structure, provides a passage for the mobile robot to enter or exit at least some of the pathways, the transport area comprising: The frame portion is formed by a plurality of beams configured to be connected to the first storage structure; as well as The floor, supported by the frame portion, includes a plurality of panels that collectively define the floor, at least one panel including one or more guide lines at predetermined locations on the at least one panel to facilitate movement of the mobile robot on the at least one panel.

2. The automated storage and retrieval system according to claim 1, wherein, The one or more guide lines include one or more magnetic guide lines, and the at least one panel further includes at least one groove configured to receive compression-fitted metallic material therein to form the one or more magnetic guide lines.

3. The automated storage and retrieval system according to claim 2, wherein, At least one mobile robot includes a magnetic sensor to detect the one or more magnetic guide lines to facilitate movement of the at least one mobile robot on the at least one panel.

4. The automated storage and retrieval system according to claim 1, wherein, The at least one panel further includes an alignment feature configured to align the one or more guide lines relative to a corresponding path in a predetermined manner, the corresponding path being configured for the mobile robot to enter and exit between the corresponding path and the at least one panel.

5. The automated storage and retrieval system according to claim 4, wherein, The alignment feature includes at least two mounting holes at a predetermined location on the at least one panel, each of the at least two mounting holes being configured to receive a fastener therein.

6. The automated storage and retrieval system according to claim 1, wherein, The at least one panel includes at least one reference mark applied to the top surface of the at least one panel, the at least one reference mark being configured to facilitate position determination and navigation by a mobile robot traveling on the floor.

7. The automated storage and retrieval system according to claim 1, wherein, The at least one panel includes at least one radio frequency identification (RFID) tag applied to the bottom surface of the at least one panel, the at least one RFID tag being configured to facilitate location determination and navigation by a mobile robot traveling on the floor.

8. The automated storage and retrieval system of claim 4, further comprising a transition plate disposed between one of the at least one panel and a corresponding passage, the transition plate being configured to connect to the alignment feature of the one panel for aligning the transition plate with the one panel and with the corresponding passage.

9. The automated storage and retrieval system of claim 1 further includes a first plurality of mounting brackets, each mounting bracket connecting a first end of each beam to a corresponding end of the first storage structure.

10. The automated storage and retrieval system of claim 9, further comprising: The second storage structure includes multiple storage locations configured to store bins containing goods, and the second storage structure includes a second plurality of passageways through which each storage location is accessible. as well as The second plurality of mounting brackets, each mounting bracket connecting the second end of each beam to the corresponding end of the second storage structure.

11. A panel for supporting a mobile robot traveling on the panel, the panel comprising: One or more magnetic guide lines are formed at predetermined positions in the top surface of the panel to facilitate the movement of the mobile robot along the top surface; At least one groove is formed in the top surface of the panel, the at least one groove being configured to receive metallic material therein to form the one or more magnetic guide lines; as well as An alignment feature is configured to align the one or more magnetic guide lines relative to a corresponding path in a predetermined manner, the corresponding path being configured for entry and exit of a mobile robot between the corresponding path and the panel.

12. The panel according to claim 11, wherein, The alignment feature includes at least two mounting holes at a predetermined location on the panel, each of the at least two mounting holes being configured to receive a fastener therein.

13. The panel of claim 11, further comprising: At least one RFID tag is applied to the bottom surface of the panel, and the at least one RFID tag is configured to facilitate location determination and navigation by a mobile robot.

14. The panel of claim 11, further comprising: At least one reference marker is applied to the top surface of the panel, the at least one reference marker being configured to facilitate position determination and navigation by a mobile robot.

15. A method for constructing a transport area for an automated storage and retrieval system, the method comprising: The frame portion of the transport area is connected to the storage structure by connecting multiple beams to the storage structure. The storage structure includes multiple storage locations configured to store bins containing goods. The storage structure includes multiple pathways, each storage location being accessible through a pathway. The pathways are configured for multiple mobile robots to traverse, each mobile robot being configured to access a storage location to store or retrieve a bin at that location. The transport area allows mobile robots to enter or exit the pathways. as well as Install a floor supported by the frame portion, the floor being formed by a plurality of panels that collectively define the floor, at least one panel including one or more guide lines at predetermined locations on the at least one panel to facilitate movement of the mobile robot on the at least one panel.

16. The method of claim 15, further comprising: Prior to the installation of the floor, at least one panel with at least one groove pre-formed therein is received, wherein the at least one groove receives compression-fitting metal material to form the one or more guide lines.

17. The method of claim 15, further comprising: After the floor is installed, at least one reference mark is applied to the at least one panel, the at least one reference mark being configured to facilitate position determination and navigation by a mobile robot traveling on the floor.

18. The method of claim 15, further comprising: After the floor is installed, at least one RFID tag is applied to the at least one panel, the at least one RFID tag being configured to facilitate location determination and navigation by a mobile robot traveling on the floor.

19. The method of claim 15, further comprising: The system receives at least one panel with alignment features that align the one or more guide lines relative to a corresponding path in a predetermined manner, the corresponding path being configured for the mobile robot to enter and exit between the corresponding path and the at least one panel.

20. The method according to claim 19, wherein, The alignment feature includes at least two mounting holes at a predetermined location on the at least one panel, each of the at least two mounting holes being configured to receive a fastener therein.

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