Systems and methods using mobile robotic stations

Abstract

Systems and methods are provided that can involve the use of mobile robot stations at a facility. In one form, a system can include a lane or deck that facilitates movement of mobile robots along the lane or deck, and a mobile robot station adjacent an edge of the lane or deck. The mobile robot station can include a door at an entrance of the mobile robot station and accessible by a mobile robot moving along the lane or deck, the door movable between a first position and a second position. The mobile robot can move into or out of the mobile robot station via the entrance when the door is in the first position, and the mobile robot is prevented from moving into or out of the mobile robot station via the entrance when the door is in the second position.

Description

[0001] Cross-reference to related applications This application claims the benefit and priority of U.S. Application No. 63 / 626,931, filed January 30, 2024, which is incorporated herein by reference in its entirety. Technical Field

[0002] The present invention generally relates to mobile robot stations, and more specifically, to stations that allow the introduction and / or removal of mobile robots at a facility. Background Technology

[0003] Automated storage and retrieval systems (ASRS) are increasingly being used in the context of fulfilling merchandise orders. In some forms, these systems may include mobile robots that move around storage structures at order fulfillment facilities to pick up and transfer containers and items. In other forms, the mobile robots may travel along various aisles within the facility.

[0004] Sometimes, mobile robots may need to be updated, repaired, or receive maintenance while moving around the facility. In these cases, there may be a need to remove these mobile robots from the system. In one respect, it would be desirable to introduce multiple robot stations, which can be temporarily or permanently fixed to or adjacent to the facility's structure, and which can isolate the mobile robots to provide safety for responding technicians. Attached Figure Description

[0005] This document discloses embodiments of systems, apparatuses, and methods relating to mobile robot stations, such as those that can be used in automated storage and retrieval systems. The description includes accompanying drawings, in which: Figure 1A This is a partial perspective view of an automated storage and retrieval system according to some embodiments; Figure 1B According to some embodiments Figure 1A A partial perspective view of an automated storage and retrieval system; Figure 2 This is a schematic diagram of a mobile robot receiving system according to some embodiments; Figure 3 , 4 5, 6 and 7 are perspective views of a mobile robot station according to some embodiments; Figure 8 , 9 10, 11, 12, 13, 14, 15, and 16 are modified according to some embodiments to include additional optional features. Figure 3 A partial perspective view of the mobile robot station; Figure 17 and 18This is a perspective view of a mobile robot station according to some embodiments; Figure 19 , 20 21 and 22 are side views of a mobile robot station according to some embodiments; Figure 23 and 24 This is a perspective view of a mobile robot receiving system according to some embodiments; Figure 25 According to some embodiments Figure 23 A top view of a mobile robot receiving system; Figure 26 According to some embodiments Figure 23 A perspective view of a mobile robot receiving system; Figure 27 According to some embodiments Figure 23 Side view of a mobile robot receiving system; Figure 28 This is a perspective view of a mobile robot receiving system according to some embodiments; Figure 29 According to some embodiments Figure 28 A top view of a mobile robot receiving system; Figure 30 According to some embodiments Figure 28 A perspective view of a mobile robot receiving system; Figure 31 According to some embodiments Figure 28 Main view of the mobile robot receiving system; Figure 32 This is a side view of a mobile robot receiving system according to some embodiments; Figure 33 This is a perspective view of a mobile robot receiving system according to some embodiments; Figure 34 According to some embodiments Figure 33 A schematic diagram of a mobile robot receiving system; Figure 35 , 36 37 and 38 are according to some embodiments Figure 33 A top view of a mobile robot receiving system; Figure 39 This is a perspective view of a mobile robot receiving system according to some embodiments; Figure 40 , 41 42, 43, 44, 45, 46 and 47 are according to some embodiments Figure 39 A top view of a mobile robot receiving system; Figure 48This is a perspective view of a mobile robot receiving system according to some embodiments; Figure 49 , 50 51, 52, and 53 are according to some embodiments Figure 48 A top view of a mobile robot receiving system; Figure 54 , 55 56 and 57 are perspective views of a mobile robot receiving system according to some embodiments; Figure 58 This is a flowchart of the process of using a mobile robot station according to some embodiments; Figure 59 This is a flowchart of the process of using a mobile robot station according to some embodiments; Figure 60 , 61 62, 63 and 64 are perspective views of a mobile robot station according to some embodiments; Figure 65 , 66 67 is a usage according to some embodiments. Figure 60 A perspective view of the mobile robot receiving system at the mobile robot station; Figure 68 According to some embodiments, it is located around the facility. Figure 60 A top view of the mobile robot station; Figure 69 According to some embodiments, it is located around the facility. Figure 60 A perspective view of the mobile robot station; and Figure 70 This is a flowchart illustrating the process of using a mobile robot station to receive a mobile robot according to some embodiments.

[0006] The elements in the accompanying drawings are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the size and / or relative positioning of some elements in the drawings may be exaggerated relative to other elements to aid in understanding the various embodiments of the invention. Furthermore, elements that are common but well-understood, useful or necessary in commercially viable embodiments are generally not depicted to provide a less obstructed view of these various embodiments of the invention. Certain actions and / or steps may be described or depicted as occurring in a specific sequence, while those skilled in the art will understand that such particularity regarding the sequence is not actually necessary. Unless otherwise set forth herein with a different specific meaning, the terms and expressions used herein have the ordinary technical meaning that those skilled in the art would assign to these terms and expressions as set forth above. Detailed Implementation

[0007] The following description should not be considered limiting, but is made merely to describe the general principles of exemplary embodiments. References throughout this specification to “a form,” “an embodiment,” “an embodiment,” “some embodiments,” “an implementation,” “some implementations,” “some applications,” or similar language mean that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment of this disclosure. Therefore, the appearance of the phrases “in one embodiment,” “in an embodiment,” “in some embodiments,” “in some implementations,” and similar language throughout this specification does not all refer to the same embodiment.

[0008] The terms “top” and “bottom”, “upper” and “lower”, and “vertical” and “horizontal” as may be used herein are for illustrative and explanatory purposes only and are not intended to limit the description of the embodiments, as the referenced items may be interchanged in position and orientation. Furthermore, as used herein, the terms “substantially” and / or “approximately” mean that the specified dimensions or parameters may vary within acceptable manufacturing tolerances for a given application.

[0009] In general, according to various embodiments, this document provides systems, apparatus, and methods for using mobile robot stations. In one form, the system includes a passageway or deck configured to facilitate the movement of a mobile robot along a walkway or deck. It further includes a mobile robot station adjacent to the edge of the walkway or deck, the mobile robot station including a first door at the entrance of the mobile robot station and accessible to the mobile robot moving along the walkway or deck, the first door being movable between a first position and a second position, wherein when in the first position, the mobile robot can move into or out of the mobile robot station via the entrance, and wherein when in the second position, the mobile robot is prevented from moving into or out of the mobile robot station via the entrance.

[0010] In some implementations, the mobile robot station includes a second door at the exit of the mobile robot station, the second door being movable between a third position and a fourth position, wherein when in the third position, the mobile robot can be moved into or out of the mobile robot station via the exit, and wherein when in the fourth position, the mobile robot cannot be moved into or out of the mobile robot station via the exit. In some implementations, the first and second doors are configured such that: when the second door is in the third position, the first door is prevented from moving to the first position; and when the first door is in the first position, the second door is prevented from moving to the third position. In some implementations, the mobile robot station further includes a lever; the first door includes a first plate configured to move vertically between an upward position and a downward position; the second door includes a second plate configured to move vertically between an upward position and a downward position; and the lever is configured to move horizontally between a first setting and a second setting, the lever blocking vertical movement of the first plate in the first setting and blocking vertical movement of the second plate in the second setting. In some implementations, the mobile robot station further includes a rotating cover comprising a first portion rotatable to open and close a first door and a second portion rotatable to open and close a second door. In some implementations, the mobile robot station further includes: a motion system configured to facilitate interface connection between the mobile robot station and an edge of a passageway or deck to position the mobile robot station in a docking position; a first blocking portion and a second blocking portion configured to extend across the passageway or deck when the mobile robot station is in the docking position; and a track ramp configured to allow movement of the mobile robot along the base of the mobile robot station. In some implementations, the system further includes a maintenance trolley adjacent to the second door of the mobile robot station, the maintenance trolley being configured to facilitate transfer of the mobile robot from the mobile robot station to the maintenance trolley. In some implementations, the system further includes control circuitry operatively coupled to the first and second doors, the control circuitry being configured to restrict movement of the first door when the second door is in a third position, and to restrict movement of the second door when the first door is in a first position. In some implementations, when the first door is in the second position, the system provides the user with access to the volume of the mobile robot station, allowing the user to insert items into and remove items from a container carried by a mobile robot within the station. In some implementations, when the first door is in the first position, the user's access to the volume of the mobile robot station is blocked, preventing the user from inserting or removing items from a container carried by a mobile robot within the station. In some implementations, the first door includes a first covering portion configured to selectively allow and block access to a container carried by a mobile robot within the mobile robot station; and the second door includes a second covering portion configured to selectively expose and block the exit of the mobile robot station.In some implementations, the mobile robot station is configured to occupy one of three states: a first state, in which a mobile robot can move into the mobile robot station through an entrance; a second state, in which a first covering portion of the mobile robot station has pivoted about an axis to block the entrance and confine the mobile robot within the mobile robot station; and a third state, in which a second covering portion has pivoted about an axis, thereby allowing user access to remove the mobile robot from the mobile robot station. In some implementations, the system further includes: a robot blocker configured in conjunction with a passageway, the robot moving along a track structure, the robot blocker being movable between a blocking position and an unblocking position that restricts the mobile robot's entry into or exit from the mobile robot station; and a roller on a first door, which moves the robot blocker from the blocking position to the unblocking position as the first door moves from a second position to a first position. In some implementations, the system further includes: a robot stop cooperating with the channel, the mobile robot moving along the track structure, the robot stop being movable between a blocking position and an unblocking position restricting the mobile robot's entry into or exit from the mobile robot station; and a support surface for the mobile robot, including a protrusion configured to be mounted to the mobile robot station and causing the robot stop to move from the blocking position to the unblocking position upon mounting. In some implementations, the system further includes: an entry port in the mobile robot station; and an entry port cover movable between an open position and a closed position, in which the entry port is uncovered and in which the entry port is covered, the first door being movable to a first position only when the entry port cover is in the closed position.

[0011] In another form, a method for receiving a mobile robot is provided, comprising: moving the mobile robot along a passageway or deck toward a mobile robot station adjacent to the edge of the passageway or deck; and moving and receiving the mobile robot through an entrance to the mobile robot station and accessible by a first door that is movable between a first position and a second position, wherein when in the first position the mobile robot can move into or out of the mobile robot station via the entrance, and wherein when in the second position the mobile robot is prevented from moving into or out of the mobile robot station via the entrance.

[0012] In some implementations, the method further includes: allowing the mobile robot to move through a second door at the exit of the mobile robot station, the second door being movable between a third position and a fourth position, wherein when in the third position, the mobile robot can be moved into or out of the mobile robot station via the exit, and wherein when in the fourth position, the mobile robot cannot be moved into or out of the mobile robot station via the exit. In some implementations, the method further includes: blocking the first door from moving to a first position when the second door is in the third position; and blocking the second door from moving to the third position when the first door is in the first position. In some implementations, the method further includes: providing a user with access to the volume of the mobile robot station when the first door is in the second position, allowing the user to insert and remove items into and from a container carried by a mobile robot within the mobile robot station. In some implementations, the method further includes: preventing the user from accessing the volume of the mobile robot station when the first door is in the first position, preventing the user from inserting items into and removing items from a container carried by a mobile robot within the mobile robot station. In some implementations, the method further includes: deactivating power to the mobile robot after it has been received into the mobile robot station. In some implementations, the method further includes: docking a maintenance trolley to a second door adjacent to the mobile robot station; and moving the deactivated mobile robot onto the maintenance trolley through the second door in a third position.

[0013] In another form, a method for receiving a mobile robot is provided, comprising: transporting a deactivated mobile robot toward a mobile robot station positioned at the edge of an adjacent passageway or deck; moving the mobile robot through an open outer door of the mobile robot station and onto a base of the mobile robot station, the outer door being movable between an open position and a closed position; closing the outer door and activating power to the mobile robot; and opening an internal door of the mobile robot station, the internal door being movable between an open position and a closed position, the internal door providing the mobile robot with access to the passageway or deck to allow the mobile robot to move along the passageway or deck; wherein when one of the outer door and the internal door is in an open position, the other of the outer door and the internal door is prevented from moving to the open position.

[0014] In one aspect, and without limitation, this disclosure generally relates to a facility, such as an order fulfillment facility, which includes multiple mobile robots (or bots) operating within the context of an automated storage and retrieval system to pick up and transfer containers. In one form, the mobile robots move around the facility and retrieve cargo containers (or bins) stored in specific storage locations within the facility as part of the automated storage and retrieval system. In certain circumstances, specific mobile robots may need to be updated or repaired. These or other similar situations may necessitate the removal of the robot from the system, possibly followed by the introduction of a new mobile robot.

[0015] Currently, any scenario requiring the removal or introduction (or import) of a robot may necessitate an emergency stop of part or all of the system—that is, a complete shutdown of all or part of the system. In one respect, and without limitation, it may be desirable to minimize the number of times a partial or complete system shutdown is required in exceptional circumstances involving mobile robots. Some accident scenarios may require individuals (such as technicians) to physically enter a portion of the system to handle the mobile robot. In such cases, the system and / or facilities may be partially or completely shut down to ensure the individual's safety.

[0016] In one aspect, and without limitation, this disclosure relates to multiple robot station concepts that may be temporarily or permanently attached to or adjacent to the structure of a facility, such as from one side of a passageway or from one side of a deck. The mobile robot station generally isolates the mobile robot to provide safety for responding technicians. In one form, the mobile robot may require some power to travel to the station and may need to communicate so that the station can prepare for the arrival of the mobile robot. Otherwise, a portion of the system may have to be shut down to remove or introduce the mobile robot. Eliminating such system downtime is desirable.

[0017] On the other hand, and without limitation, this disclosure relates to a mobile robot station system with additional capabilities, allowing it to operate as a more general-purpose workstation. Such a mobile robot station system allows users to safely interact with mobile robots in a variety of ways. More specifically, the system is intended to allow users to safely perform one or more of the following: (1) gain access to a product carried by the mobile robot or to store a product at the mobile robot; (2) gain access to the mobile robot to introduce or remove a bin from the mobile robot; and (3) gain access to the mobile robot to introduce or remove the mobile robot itself from an operational section (or work area) of the facility. In one form, the mobile robot station can act as a parking area for mobile robots outside of traffic flow to other mobile robots, and may also allow mobile robots to recharge themselves at the station.

[0018] Figure 1AA partial view of an embodiment of an order fulfillment facility 100 is shown, illustrating a storage structure 102 comprising a plurality of bin rows 104 consisting of storage locations 106. Specifically, each bin row 104 includes a yz array of storage locations 106 arranged in horizontal rows, and a transfer tower or vertical tower along the rows. As explained below, a mobile robot 150 can travel in the z-direction between storage layers within the transfer tower. Pairs of bin rows 104 can be arranged facing each other, separated by aisles 108. In one embodiment, the aisle is intended to be a passageway 108. The passageway 108 may have a width such that a mobile robot 150 traveling within the passageway 108 can transfer bins to bin rows 104 on either side of the passageway 108. As described below, the passageway 108 may be wide enough to allow personnel to enter the passageway 108 between bin rows 104 for repair or otherwise maintenance of components within the passageway 108.

[0019] The order fulfillment facility 100 may further include decks 112 (or transfer planes or areas) spaced apart at different horizontal levels of the storage structure 102. The decks 112 may extend between aisles 108, allowing the robot 150 to maneuver in the xy plane of each deck 112 to travel between different aisles 108. In some embodiments, the decks 112 may be vertically spaced apart, allowing technicians access to all areas within an aisle 108 served by a particular deck 112. The spacing between the decks 112 may vary in different embodiments. In addition to providing access to the aisles 108, each pair of decks 112 allows the mobile robot 150 to move to / from workstation 110. In some forms, the mobile robot 150 may come to workstation 110 from a first deck 112-1 and leave workstation 110 from a second deck 112-2. Alternatively, in some forms, the mobile robot 150 may come to workstation 110 from deck 112-2 and leave from the first deck 112-1.

[0020] Figure 1B An example of workstation 110 is shown. In some embodiments, each workstation 110 is equipped to receive a pair of mobile robots 150. A first mobile robot 150 at workstation 110 may carry a product container (or bin) containing items for fulfilling product requests. A second mobile robot 150 at workstation 110 may carry an order container (or bin) in which items from the product bin are placed to fulfill product requests. Workers at workstation 110 manually transfer items from the product bin to the order bin under the guidance of an inventory control system at workstation 110.

[0021] Mobile robots 150, carrying both product and order bins, arrive from one of the decks (e.g., deck 112-1). Once items are transferred from the product bin to the order bin, mobile robot 150 can leave workstation 110, for example, via deck 112-2. Mobile robots 150 carrying both product and order bins continuously cycle through workstation 110. Figure 1A In this configuration, each workstation 110 is served by a single deck 112, which serves as both the entrance and exit for the workstation 110. Further details regarding the structure and operation of embodiments of the workstations are disclosed in U.S. Patent Nos. 10,040,632 and 11,142,398, which are incorporated herein by reference in their entirety. In some forms, as further described below, it may be desirable to attach or position a mobile robot station to or adjacent to aisle 108 or deck 112, which can receive mobile robots 150 requiring service.

[0022] As mentioned above, the order fulfillment facility 100 may further include a plurality of mobile robots 150 for transferring bins or other product containers to and from storage locations 106 in the workstation 110 and the storage location 106 in the storage location 104. In some embodiments, the mobile robots 150 may be self-guided for horizontal movement within the aisle 108 to transfer bins or other product containers between the mobile robots 150 and the storage locations 106. For example, a track system including horizontal rails may be anchored to the storage location 104 within the aisle 108 at different vertical levels. The horizontal rails provide access to storage shelves on either side of the aisle 108 in the x-direction on a given level. As mentioned above, the storage location 104 may include a transfer tower, within which the mobile robots 150 may travel vertically between the levels of the storage locations 106 in the z-direction.

[0023] In another form, the track system may be in the form of guide lines, such as magnetic guide lines, which may include navigation aids such as RFID tags. Thus, the track system may include horizontal tracks, guide lines, and / or some combination thereof. In one example, horizontal tracks may be used in aisle 108, while guide lines may be embedded in panels forming at least some decks 112. Deck 112 allows the mobile robot 150 to travel between aisles at different levels of storage structure 102. Further details of the storage structure, track system, and mobile robot 150 that can be used in conjunction with the present technology are described, for example, in the following U.S. patents: U.S. Patent No. 9,139,363; U.S. Patent No. 10,435,241; and the previously mentioned U.S. Patent No. 11,142,398, each of which is incorporated herein by reference in its entirety.

[0024] Therefore, in some forms, a facility 100 is disclosed, having a passageway 108 and a deck 112, and a mobile robot 150 configured to move along the passageway 108 and the deck 112 at the facility 100. The facility 100 may be in the form of an order fulfillment facility, including storage locations 106 for storing containers containing goods / items, each storage location 106 being accessible via the passageway 108. Furthermore, the mobile robot 150 is configured to access the storage locations 106 to store or retrieve containers at the storage locations 106.

[0025] The aforementioned order fulfillment facility 100 is an example of a facility 100 in which mobile robots 150 move around to perform certain tasks. During such movement, mobile robots 150 may encounter situations that cause them to be damaged, impair certain functions, or otherwise require repair. These situations may be internal (such as internal component failure) or external (such as collision with an obstacle). In these cases, it is desirable to localize the problem by moving the mobile robot to a station so that the entire facility (or a large portion thereof) does not have to be shut down. The methods described in this disclosure may generally involve using a mobile robot station within facility 100 to create an isolation zone, or some kind of airlock, around the damaged or malfunctioning mobile robot 150 until it can be deactivated and removed to a safe area.

[0026] Figure 2 A schematic example of a mobile robot receiving system 200 is shown. Generally, the system 200 is intended to involve a mobile robot station that can be used to isolate and remove mobile robots that may be damaged or require some form of maintenance. The system 200 is also intended to be used to introduce new mobile robots, such as, for example, introducing a functional mobile robot as a replacement or substitute for a malfunctioning mobile robot. This new mobile robot can then, for example, perform the order fulfillment task that the replaced mobile robot was performing.

[0027] In one form, such as Figure 2 As shown, the mobile receiving system 200 includes a channel 202 or deck 204 configured to facilitate the movement of a mobile robot 206 along a channel 202 or deck 204. For example, the channel 202 or deck 204 may include some form of navigation system to guide the movement of the mobile robot 206, such as, but not limited to, a track / rail system, painted or magnetic guide lines, RFID tags, reference markers, etc. Furthermore, as can be seen, in one form, it is anticipated that the channel 202, deck 204, and mobile robot 206 may all be included in a facility 208, such as, for example, an order fulfillment facility having storage locations 210 for storing various types of items / goods.

[0028] The mobile robot receiving system 200 also includes a mobile robot station 212 disposed at the edge of the passageway 202 or deck 204, adjacent to or near it. In one embodiment, the mobile robot station 212 may include: a base 214 for supporting a mobile robot; a first door 216 accessible to a mobile robot 206 moving along the passageway 202 or deck 204, the first door 216 being movable between a first position and a second position; and a second door 218 movable between a third position and a fourth position. In one embodiment, the first and third positions are open positions, and the second and fourth positions are closed positions. Furthermore, in this embodiment, the first door 216 may be located at the entrance of the mobile robot station 212 and accessible to a mobile robot 206 moving along the passageway 202 or deck 204. In other words, the first door 216 is movable between a first position and a second position, wherein when in the first position, the mobile robot 206 can move into or out of the mobile robot station 212 via the entrance, and wherein when in the second position, the mobile robot 206 is prevented from moving into or out of the mobile robot station 212 via the entrance.

[0029] Furthermore, in one embodiment, the mobile robot station 212 may include a second door 218. The second door 218 may be located at the exit of the mobile robot station 212. In other words, the second door 218 may move between a third position and a fourth position, wherein when in the third position, the mobile robot 206 may be moved into or out of the mobile robot station 212 via the exit, and wherein when in the fourth position, the mobile robot 206 may not be moved into or out of the mobile robot station 212 via the exit.

[0030] In some configurations, for safety purposes, the first door 216 and the second door 218 can be configured such that when the first door 216 is in the open position, the second door 218 is prevented from moving to the open position. In other words, when the second door 218 is in the third position, the first door 216 is prevented from moving to the first position, and when the first door 216 is in the first position, the second door 218 is prevented from moving to the third position. Therefore, doors 216 and 218 can be interlinked and will not open simultaneously. The doors 216 and 218 of the mobile robot station 212 can be considered to form a coarse airlock for receiving the mobile robot 206.

[0031] In one embodiment, the mobile robot station 212 is expected to include a charging rail or part of a charger 219 connected to the electrical infrastructure of facility 208. A mobile robot 206 entering and occupying the mobile robot station 212 can utilize this charger 219 to recharge its power. As an example, the mobile robot 206 may include a pinion that can extend to engage the charger 219 for recharging, and then retract when recharging is complete.

[0032] Alternatively, system 200 may include a maintenance (or transport) cart 220 positioned adjacent to the second door 218. The maintenance cart 220 is located close to the second door 218 to facilitate the transfer of mobile robot 206 from mobile robot station 212 to the maintenance cart 220. The maintenance cart can then transport mobile robot 206 to a maintenance area, such as for repair or to perform maintenance on mobile robot 206.

[0033] In one embodiment, the mobile robot receiving system 200 is expected to include sensors 222 configured to detect the presence of the mobile robot 206 in the mobile robot station 212. Any variety of sensors can be used, including, for example, weight sensors, proximity sensors, pressure sensors, motion detectors / sensors, position sensors, etc. Depending on the type of sensor 222, it can be located at the mobile robot station 212 or it can be positioned at a remote location. These sensors 222 can be coupled to or coordinated with the first and second doors 216, 218 to trigger their opening and closing by detecting the mobile robot 206.

[0034] In one embodiment, the system 200 is expected to include control circuitry 224 operatively coupled to the first door 216 and the second door 218. Control circuitry 224 may be configured to restrict movement of one of the first and second doors 216, 218 when the other is in an open position. In other words, control circuitry 224 may be operatively coupled to the first door 216 and the second door 218 and may be configured to restrict movement of the first door 216 when the second door 218 is in a third position and restrict movement of the second door 218 when the first door 216 is in a first position. Control circuitry 224 may be coupled to sensor 222 such that when the sensor detects that the mobile robot 206 is in a certain position, the detection may trigger the opening of one of the first and second doors 216, 218 or the closing of one or both of the first and / or second doors 216 / 218. Control circuitry 224 may be located wholly or partially at the mobile robot station 212 or at a remote location.

[0035] In this context, the term control circuit 224 broadly refers to any microcontroller, computer, or processor-based device having a processor, memory, and programmable input / output peripherals, generally designed to manage the operation of other components and devices. Further understanding includes common accompanying accessory devices, including memory, transceivers for communicating with other components and devices, etc. These architectural options are well known and understood in the art and need not be further described herein. Control circuit 224 can be configured (e.g., by using appropriate programming stored in memory, as will be well understood by those skilled in the art) to perform one or more steps, actions, and / or functions described herein.

[0036] As described above, control circuitry 224 may include or be coupled to common accompanying accessories, such as, for example, memory, network interfaces, and wireless networks. Memory may, for example, non-transitory store computer instructions that, when executed, cause control circuitry 224 to operate as described herein, as is well known in the art. Furthermore, network interfaces enable control circuitry 224 to communicate with other components (internal and external to the system). Such network interfaces are well understood in the art. Network interfaces can communicatively couple control circuitry 224 to wireless networks and any other networks that may be appropriate as appropriate. While one control circuitry 224 is shown, in some forms, the functionality of control circuitry 224 may be implemented on multiple processor devices communicating over a network.

[0037] Figure 3-7 An example of a mobile robot station 300 is shown, in which a mobile robot 301 is set. Figure 3 A mobile robot station 300 is shown, with a first door 302 in the closed position and a second door 304 in the open position. The mobile robot station 300 includes a sliding lever 306, shown positioned to allow the second door 304 to move downwards to the open position. Simultaneously, the sliding lever 306 holds the first door 302 in the raised closed position and prevents it from moving downwards to the open position. Therefore, this configuration uses a mechanical mechanism to prevent both doors 302 and 304 from opening simultaneously, rather than employing control circuitry / sensors.

[0038] As can be seen, in this particular configuration, the mobile robot station 300 includes a sliding rod 306, the first door 302 generally includes a first sliding plate 320 configured to move vertically between an upward position and a downward position, and the second door 304 generally includes a second sliding plate 322 configured to move vertically between an upward position and a downward position. In this configuration, the sliding rod 306 slides horizontally between the first and second configurations, blocking vertical movement of the first sliding plate 320 in the first configuration and blocking vertical movement of the second sliding plate 322 in the second configuration. Figure 3 In the middle, the sliding rod 306 is in the first setting.

[0039] Figure 3 A maintenance trolley 310 is also shown next to the open second door 304 of the mobile robot station 300. In one embodiment, the maintenance trolley 310 includes some form of movement device, such as wheels 312, to allow the maintenance trolley 310 to be positioned next to the second door 304 and to allow the maintenance trolley 310 to transport the mobile robot 301 to the maintenance area. In one embodiment, the height of the maintenance trolley 310 is expected to be adjustable (e.g., via jacks) so that its support surface 314 is flush with the base of the mobile robot station 300. Furthermore, in some embodiments, alignment features (such as pins) are expected to be used to temporarily connect and align the mobile robot station 300 and the maintenance trolley 310 to allow the mobile robot 301 to move from the station 300 to the trolley 310.

[0040] In some forms, it is anticipated that power to the mobile robot 301 is deactivated once it has been moved into the mobile robot station 300. In some forms, it is anticipated that the mobile robot station 300 can be opened from the top to allow a technician to manually deactivate the mobile robot 301 upon its arrival, possibly with both doors in the closed position. After deactivation, the mobile robot 301 can be moved to the maintenance cart 310. Generally, it is anticipated that various types of bases 214 can be used in the mobile robot station 212, including, for example, fixed floors or movable floors (such as sliding or rolling floors). In one form, the base 214 of the mobile robot station 300 can be moved as the mobile robot 301 rests on the base 214, such that the base 214 is moved onto the support surface 314 of the maintenance cart 310. In another form, the mobile robot 301 can be rolled onto the support surface 314 of the maintenance cart 310. In another form, the base 214 may be in the form of a track or other support, and the mobile robot 301 may move from the mobile robot station 300 to the maintenance cart 310 along these tracks or supports.

[0041] Figure 4The mobile robot station 300 is shown again, with the second door 304 in the open position. The sliding lever 306 is in the first position, in which downward movement of the first door 302 is blocked. Figure 4 A mobile robot station 300 is shown, which has two side walls 316 that enclose the sides of the mobile robot station 300 and a ceiling 318 that covers the top of the station 300. Figure 5 The image generally shows the mobile robot station 300, with the second door 304 in the open position, but not... Figure 4 The side walls 316 and the ceiling 318.

[0042] Figure 6 A mobile robot station 300 is shown, with the first door 302 in the open position. A sliding lever 306 has been moved rearward (towards the second door 304), placing it in a second position. This displacement of the sliding lever 306 allows the first door 302 to move downwards but simultaneously blocks the movement of the second door 304. Figure 6 A mobile robot station 300 is shown, which has two side walls 316 (which can be modified to include cutout portions 317) enclosing both sides of the mobile robot station 300 and has a ceiling 318 covering the top of the station 300. Figure 7 The mobile robot station 300 is generally shown, with the first door 302 in the open position and the second door 304 in the closed position, but not... Figure 6 The side walls 316 and the ceiling 318.

[0043] In some configurations, the slider 306 is generally expected to occupy three different settings, placing the mobile robot station 300 in three different states. In a first setting, the slider 306 blocks downward movement of the first door 302 (first door closed) while allowing downward movement of the second door 304 (second door open). In a second setting, the slider 306 allows downward movement of the first door 302 (first door open) while blocking downward movement of the second door 304 (second door closed). However, a further intermediate third setting is anticipated, in which the slider 306 blocks downward movement of both the first and second doors 302 and 304 (both first and second doors closed). This intermediate third setting may be desirable for completely isolating the mobile robot 301, such as, for example, to allow the mobile robot 301 to be deactivated.

[0044] While a lever is provided as an example of a door control mechanism, other types of doors and other door control mechanisms are also considered. For example, vertical pivot doors, swing doors, horizontal sliding doors, retractable doors, folding doors, etc., are considered. Other door control mechanisms, such as various locking and latching mechanisms, are also considered. These other types of doors and door control mechanisms allow at least alternation between the first two settings / states described above. Furthermore, optionally, they may allow alternation with the third intermediate setting / state described above.

[0045] Figure 8-16 The mobile robot station 300 with some additional optional features is shown. Figure 8 and 9 The first door 302 (or interior door) is shown in both the closed and open positions. In this configuration, the mobile robot station 300 is expected to include two robot barriers 324 on either side. In one configuration, these robot barriers 324 may be incorporated into the track structure 325 along which the mobile robot 301 travels, and they may be in an engaged position in which they can block the wheels 312 (or other motion mechanisms) of the mobile robot 301 to prevent the mobile robot 301 from entering or exiting. As an example, these robot barriers 324 may be metallic components and / or friction materials, which may be introduced into or removed from the passageway of the mobile robot 301. Examples of robot barriers and further details regarding their construction and operation are disclosed in PCT Publication No. WO 2024 / 076682, which is incorporated herein by reference in its entirety. Figure 8 In the middle, the first door 302 closes and the robot blocker 324 engages. Figure 9 In the middle, the first door 302 is opened. In this open position, the rollers 326 on the first door 302 have been used to separate the robot blocks 324, so that they no longer block the entry or exit of the mobile robot 301.

[0046] Next, Figure 10-13 The illustration shows the use of optional features on the maintenance trolley 310 (or transport trolley) to cooperate with the second door 304 (or outer door). This form also includes a robot blocker 328 that can be engaged to block the mobile robot 301 and disengaged to allow the mobile robot 301 to move. However, in this form, the second door 304 does not include rollers or other mechanisms for disengaging the robot blocker 328 when the second door 304 is lowered.

[0047] Conversely, maintenance trolley 310 must be docked to detach robot blocker 328. In one form, such as Figure 10 and 11As can be seen, the support surface 314 of the maintenance cart 310 may include two protrusions or flanges 330 extending on both sides of the support surface 314. These flanges 330 may directly engage the robot stops 328 to move them from a stopped position to an unstopped position. Alternatively, these flanges 330 may engage a mechanism that further causes the robot stops 328 to move from a stopped position to an unstopped position.

[0048] exist Figure 12 In the middle, the second door 304 is open, but the robot blocker 328 remains in the blocking position (the maintenance cart 301 is not yet in place). Figure 13 In this configuration, the support surface 314 has been inserted, causing the protrusions / flanges 330 to move the robot blocker 328 to an unblocking position (maintenance cart 301 is in place). Using these protrusions / flanges 330 helps ensure that the mobile robot 301 cannot exit through the open second door 304 until the maintenance cart 301 is in a position ready to receive the mobile robot 301.

[0049] Figure 14-16 Additional optional features are shown in the form of an access port 332. This access port 332 is located on one side of the mobile robot station 301 and allows technicians to access the mobile robot 30, for example, to perform maintenance or repair on the mobile robot 301 or to retrieve containers from the mobile robot 301. In one form, the access port 332 may be coupled to the open or closed state of a door. As an example, in one form, the access port 332 can only be opened when the first door 302 is closed.

[0050] Figure 14-16 An operational example of entry port 332 depending on the states of doors 302 and 304 is shown. Figure 14 If the first door 302 (inner door) is opened, the mechanical interlock requires the second door 304 (outer door) to close, and because the second door 304 is closed, the second door handle 334 prevents the entry port 332 from opening. More specifically, the entry port cover 333 prevents the entry port 332 from opening, and the second door handle 334 prevents the entry port cover 333 from moving downwards along the slot 335 to the open position. Figure 15 In the case where the second door 304 is open, the second door handle 334 is downward, and the inlet port cover 333 can move freely downward, allowing the inlet port 332 to open. Figure 16In this configuration, the access port cover 333 has been moved downwards, and the access port 332 is open. In one embodiment, the second door 304 cannot be closed without first closing the access port 332, and the first door 302 can only be opened when both the second door 304 and the access port 332 are closed. Optionally, a graphical user interface 336 may be included on the housing adjacent to the access port 332.

[0051] Figure 17 and 18 Another example of a mobile robot station 400 is shown. In this form, the mobile robot station 400 uses a one-piece rotating cover 402, which has a front and a rear section that operate as a first door and a second door, respectively. The rotating cover 402 can be rotated about a pivot axis 404 to open and close the first and second doors. The pivot axis 404 allows the rotating cover 402 to rotate such that portions of it are below the base 406 in different positions / states. Figure 18 The mobile robot station 400 with sidewalls 408 is shown.

[0052] In the first position / state, the rotating cover 402 is rotated such that a portion of the rotating cover 402 blocks access from the front (first door closed), while the rotating cover 402 allows access from the rear (second door open). In the second position / state, as... Figure 17 and 18 As shown, the rotating cover 402 has rotated about the pivot axis 404, such that the cover 402 allows access from the front (first door open), while a portion of the rotating cover 402 blocks access from the rear (second door closed). The size of the rotating cover 402 is preferably chosen (and coordinated with the size of the mobile robot) such that when one side is open, a portion of the cover 402 on the other side is at a sufficiently low height to prevent the mobile robot from exiting from the other side. A third intermediate position / state is also considered. In this third position / state, the rotating cover 402 is positioned such that it partially blocks both the front and rear sides (both the first and second doors are in the closed position).

[0053] Figure 19-22 Another example of a mobile robot station 500 is shown. In this form, the mobile robot station 500 uses a two-piece rotating cover 501, which includes two discrete and interlocking rotating cover portions 502, 504; that is, it uses a front rotating cover portion 502 and a rear rotating cover portion 504. These front and rear rotating cover portions 502, 504 operate as a first door and a second door, respectively. Each rotating cover portion 502, 504 can be rotated independently to open and close the first and second doors, respectively. In one form, the cover portions 502, 504 can be of the nature of an inner shell and an outer shell, which generally share the same axis of rotation.

[0054] In the first position / state, such as Figure 20 As shown, the front rotating cover portion 502 is rotated to block access from the front (first door closed), while the rear rotating cover portion 502 is rotated to allow access from the rear (second door open). In the second position / state, as... Figure 22 As shown, the front rotating cover portion 502 has been rotated to allow access from the front (first door open), while the rear rotating cover portion 502 has been rotated to block access from the rear (second door closed). The rotating cover portions 502 and 504 are coordinated such that when one portion is in the open position on one side, the other portion cannot be moved to the open position on the other side. For example, in one form, this positioning mechanically prevents movement of the other portion when one portion has been rotated and locked in the open position. A third intermediate position / state is also considered, such as... Figure 19 and 21 As shown. In this third position / state, both rotating cover portions 502, 504 are positioned such that they block both the front and rear sides (both the first and second doors are in the closed position).

[0055] Next, it is desirable to position the mobile robot stations (such as mobile robot stations 212, 300, 400, and 500 described above) in an area of ​​facility 100. In one form, it is preferable to position the mobile robot stations in an area that does not interfere with the general movement and operation of the mobile robots. In other words, it may be desirable to position the mobile robot stations in areas where mobile robots may need to navigate around them and where there is no risk of the mobile robots colliding with them (and potentially damaging themselves and / or the station).

[0056] Figure 23-27 A mobile robot receiving system 600 is shown positioned adjacent to deck (or transfer plane / area) 602. The mobile receiving system 600 includes a mobile robot station 604 and a maintenance cart 606. In one embodiment, the mobile robot receiving system 600 may include, but is not limited to, any one of the mobile robot stations 212, 300, 400, and 500 described above and their components. It is also contemplated that the mobile robot receiving system 600 may include, but is not limited to, the maintenance cart 310 described above and its components.

[0057] The attached diagram shows a portion of facility 100, with some structural details removed for clarity. Figure 23 and Figure 24 They are similar to each other, but... Figure 24The diagram shows the removal of a portion of the facility structure. A mobile robot 608 moves up and down along aisle 610 to store and / or retrieve containers (or bins) at storage location 612. The end of aisle 610 allows the mobile robot 608 to access or exit deck 602. In this configuration, deck 602 provides the mobile robot 608 with access to the mobile receiving system 600.

[0058] In this configuration, the mobile robot station 604 (and the mobile robot receiving system 600) is positioned adjacent to the end of the deck 602, offset from the deck 602 and adjacent to its edge. The mobile robot station 604 is preferably configured such that a first door 614 of the mobile robot station 604 allows access by a mobile robot 608 entering from the deck 602. Furthermore, it is preferably configured such that a second door 616 of the mobile robot station 604 is adjacent to the maintenance cart 606. Figure 27 As can be seen, the base 618 of the mobile robot station 604 is preferably positioned at the same height level as the deck 602, which is also preferably at the same height as the support surface 620 of the maintenance trolley 606, to allow the mobile robot 608 to move horizontally from the deck 602 to the mobile robot station 604 and to the maintenance trolley 606. This general movement can also be reversed to allow the introduction of a new mobile robot 608 from the maintenance trolley 606 (or from the mobile robot station 604) onto the deck 602. In some forms, the mobile robot station 604 and / or the maintenance trolley 606 may include components 622 to allow the heights of the base 618 and / or the support surface 620 to be adjusted to match the height of the deck 602.

[0059] Figure 28-32 A mobile robot receiving system 700 is shown positioned at the end of an adjacent passageway 710. The mobile receiving system 700 includes a mobile robot station 704 and a maintenance cart 706. In one embodiment, the mobile robot receiving system 700 may include, but is not limited to, any one of the mobile robot stations 212, 300, 400, and 500 described above and their components. It is also contemplated that the mobile robot receiving system 700 may include, but is not limited to, the maintenance cart 310 described above and its components.

[0060] and Figure 23-27 Same, Figure 28-32 A portion of facility 100 is shown, with some structural details omitted for clarity. A mobile robot 708 moves up and down along aisle 710 to store and / or retrieve containers (or bins) at storage location 712. The end of aisle 710 allows the mobile robot 708 to access and exit deck 702. In this configuration, aisle 710 provides the mobile robot 708 with access to the mobile receiving system 700.

[0061] In this configuration, the mobile robot station 704 (and the mobile robot receiving system 700) is positioned adjacent to the end of the passageway 710, offset from the passageway 710 and adjacent to its edge. The mobile robot station 704 is preferably configured such that a first door 714 of the mobile robot station 704 allows access by a mobile robot 708 entering from the passageway 710. Furthermore, it is preferably configured such that a second door 716 of the mobile robot station 704 is adjacent to the maintenance cart 706. As can be seen, the base 718 of the mobile robot station 704 is preferably positioned at the same height level as the passageway 710, which is also preferably at the same height as the support surface 720 of the maintenance cart 706, to allow the mobile robot 708 to move horizontally from the passageway 710 to the mobile robot station 704 and to the maintenance cart 706. This general movement can also be reversed to allow the introduction of a new mobile robot 708 from the maintenance cart 706 (or from the mobile robot station 704) onto the deck 702. In some forms, the mobile robot station 704 and / or maintenance trolley 706 may include component 722 to allow adjustment of the height of the base 718 and / or support surface 720 to match the height of the aisle 710.

[0062] Figure 33-38 Another example of a mobile robot receiving system 800 is shown. In this form, the mobile robot receiving system 800 includes an integrated mobile robot station 802 (or “smart cart”) that docks to a structure (without a separate maintenance cart). In the figures, the mobile robot station 802 can be seen docking to deck 804 (or transfer plane or transfer area), but it is also contemplated that in some cases, the mobile robot station 802 may also dock to the end of aisle 806. As can be seen, the mobile robot station 802 preferably has some form of mobility device (such as wheels 808) to allow the mobile robot station 802 to dock at different desired locations on deck 804 and aisle 806. Once in the docked position, the mobile robot station 802 can then receive the mobile robot 810 and move it to the maintenance area for servicing and repair.

[0063] Figure 33 and 34 Mobile robot station 802 is displayed. Figure 33A mobile robot station 802 is shown, having a motion device 808 to facilitate interface connection between the mobile robot station 802 and the end of a passageway 806 or deck 804, thereby positioning the mobile robot station 802 in a docking position. The mobile robot station 802 also includes a first blocking portion 812 and a second blocking portion 814, which generally serve as sidewalls when the mobile robot station 802 is receiving a mobile robot 810. When the mobile robot station 802 is in the docking position, the first and second blocking portions 812, 814 extend across the passageway 806 or deck 804. The mobile robot station 802 also preferably includes a base or support surface 816 for receiving the mobile robot 810 thereon.

[0064] Figure 34 This is a schematic diagram showing a mobile robot station 802 with possible additional features. Figure 34 A mobile robot station 802 is shown in a docking position, with a portion of the station extending over deck 804. The mobile robot station 802 includes first and second blocking portions 812, 814 that can function as sidewalls. It further includes a first door 818 that can be in an open position to receive a mobile robot 810 and then closed. It may further include a second door 820 that can move between open and closed positions, but in some forms, the second door 820 is not required. The mobile robot station 802 may also include one or more track ramps 822 to facilitate movement of the mobile robot along a base or support surface 816 of the station and to help secure the mobile robot within the station 802. The mobile robot station 802 may also include a third blocking portion 824 at the rear of the station to prevent rearward movement of the mobile robot 810 once it has been received into the station 802.

[0065] In some configurations, a first door 818 and one or more sensors 222 are intended to create a self-contained security area. Sensors 222, in conjunction with control circuitry 224, can be used to trigger the opening of the first door 818 to receive the mobile robot 810, and can also trigger the closing of the first door 818 after the mobile robot 810 has been received into the station 802. This mobile robot station 802 (smart cart) allows the robot to be removed (and, in some instances, introduced) into the work area without permanent space occupation of a portion of the deck 804 or aisle 806.

[0066] Figures 35-38 The diagram shows several different stages of receiving the mobile robot 810 at the mobile robot station 802. Figure 35 and 36The image shows a mobile robot 810 moving along deck 804 in the direction of a docked mobile robot station 802. The mobile robot station 802 extends its first and second blocking portions 812, 814 over deck 804, and the first door 818 is opened. Figure 37 The image shows the mobile robot 810 being received into station 802 through the opened first door 818, and... Figure 38 The first door 818 is shown to be in the closed position. The mobile robot 810 can then move to the base / support surface, and the mobile robot station 802 can then leave or detach from the docking of the deck 804.

[0067] Figures 39-47 Another example of a mobile robot receiving system 900 is shown. In this form, the mobile robot receiving system 900 includes a permanent mobile robot station 902, which is fixed adjacent to the end of deck 904. However, it is also considered that in some cases, the mobile robot station 902 may also be fixed adjacent to the end of aisle 906. In fact, by adding a permanent structure to the end of deck 904 (or aisle 906), this example is adding an extension to deck 904 (or aisle 906) and thus increasing the footprint of deck 904 (or aisle 906).

[0068] In this configuration, the mobile robot station 902 is generally expected to function as a basic external airlock on deck 904 (or passageway 906). Regarding the accompanying drawings, the mobile robot station 902 has a first (or internal) door 908 controlling access to and exit from deck 904, and a second (or external) door 910 controlling external access. In some configurations, such as... Figure 39 As shown, the mobile robot station 902 may optionally have sidewalls 912 to help ensure that the mobile robot 914 is secured in the station 902.

[0069] As previously stated, it is generally expected that the two doors 908 and 910 cannot be opened simultaneously. For safety reasons, the first (internal) door 908 should be closed before the second (external) door 910 can be opened. This condition can be achieved, for example, through mechanical coupling and operation (such as by sliding bar 306) or through electrical coupling and operation (such as by control circuitry 224 operating in conjunction with sensor 222 and software). Additionally, alternatively, the operator may need to shut down or deactivate the mobile robot 914 before opening the second (external) door 910, and / or the maintenance cart 916 may need to be present before opening the second (external) door 910. The mobile robot station 902 may also include navigation aids, such as magnetic guide lines or RFID tags, disposed in its base 917 to allow the mobile robot 914 to know its location during its activity and to allow it to move into the mobile robot station 902.

[0070] Figures 40-47 The diagram shows several different stages of receiving the mobile robot 914 at the mobile robot station 902. Figure 40 and 41 The image shows mobile robot 914 moving in the direction of mobile robot station 902. Figure 42 It shows that mobile robot 914 has entered mobile robot station 902 through the opened first door 908, and after entering, Figure 43 The first door, 908, was shown to be closed. Figure 44 and 45 The diagram shows the second door 910 opening and the maintenance trolley 916 positioned adjacent to the second door 910 to receive the mobile robot 914 from the mobile robot station 902. This general action can also be reversed to introduce a new mobile robot 914 from the maintenance trolley 916 (or from the mobile robot station 902) onto the deck 904.

[0071] although Figures 40-45 The image shows a mobile robot station 902 with doors 908 and 910 positioned relative to each other, but the positions of these doors are not essential. For example, Figure 46 and 47 The second (external) door 910 and maintenance cart 916 are shown positioned on the left side of the mobile robot station 902, such that the two doors 908, 910 do not face each other. In one embodiment, if the mobile robot station 902 uses door 910 on the side of station 902, the base 917 may include a sliding platform to slide the mobile robot 914 onto the cart.

[0072] Figures 48-53 Another example of a mobile robot receiving system 1000 is shown. In this form, such as... Figure 48 As can be seen, the mobile robot receiving system 1000 includes a permanent mobile robot station 1002, which is installed in a dedicated location on deck 1004. However, it is also considered that in some cases, the mobile robot station 1002 may also be installed in a dedicated location at the end of a passageway 1006. The mobile robot station 1002 is similar to the previously described station 902, but in this form, the station 1002 is installed on deck 1004 (or in passageway 1006), rather than beside its end. The mobile robot station 1002 is preferably positioned at the end of deck 1004 (or passageway 1006) so that maintenance trolley 1016 can be positioned outside the end of deck 1004 (or passageway 1006). In this form, the mobile robot 1014 may have to navigate around the mobile robot station 1002 on deck 1004.

[0073] In this configuration, the mobile robot station 1002 is again expected to function as a basic external airlock on the deck 1004 (or passageway 1006). Regarding the accompanying drawings, the mobile robot station 1002 has a first (or internal) door 1008 controlling access to and exit from the deck 1004, and a second (or external) door 1010 controlling external access. Generally, the mobile robot station 1002 is expected to have sidewalls 1012 to help ensure that the mobile robot 1014 is secured within the station 1002.

[0074] Similar to station 902 described above, it is generally expected that the two doors 1008 and 1010 cannot be opened simultaneously. For safety reasons, the first (internal) door 1008 should be closed before the second (external) door 1010 can be opened. This condition can be achieved, for example, through mechanical coupling and operation (such as by sliding bar 306) or through electrical coupling and operation (such as by control circuitry 224 operating in conjunction with sensor 222 and software). Additionally, alternatively, the operator may need to shut down or deactivate mobile robot 1014 before opening the second (external) door 1010, and / or maintenance cart 1016 may need to be present before opening the second (external) door 1010. The base 1017 of mobile robot station 1002 may be part of deck 1004 or a separate surface mounted on top of deck 1004. In either case, the base 1017 may also include navigation aids, such as magnetic guide lines or RFID tags, disposed therein, to allow the mobile robot 1014 to know its location while it is active and to allow it to move into the mobile robot station 1002.

[0075] Figures 49-53 The diagram shows several different stages of receiving the mobile robot 1014 at the mobile robot station 1002. Figure 49 and 50 The image shows the mobile robot 1014 moving in the direction of the mobile robot station 1002. Figure 51 It shows that mobile robot 1014 has entered mobile robot station 1002 through the first opened door 1008, and after entering, Figure 52 It shows that the first door, 1008, is closed. Figure 53 The diagram shows the second door 1010 open and maintenance trolley 1016 positioned adjacent to the second door 1010 to receive mobile robot 1014 from mobile robot station 1002. This general action can also be reversed to introduce a new mobile robot 1014 from maintenance trolley 1016 (or from mobile robot station 1002) onto deck 1004. In one embodiment, alternatively, mobile robot station 1002 may be configured such that it can be rotated away from the road when not in use, so that it is no longer located above deck 1004 (or passageway 1006).

[0076] Figures 54-57 Another example of a mobile robot receiving system 1100 is shown. This system 1100 uses a different approach than the systems described above. For example... Figure 54 As can be seen, the mobile robot receiving system 1100 includes a mobile robot station 1102. The mobile robot station 1102 includes a motion device 1104 and a height adjustment assembly 1106 to allow the base or support surface 1108 to be raised to different heights (such as a jack). The mobile robot station 1102 also includes one or more forklift teeth or arms 1110 (preferably two arms 1110) attached to and supported by the base / support surface 1108. The arms 1110 are designed to support and lift the mobile robot 1112 so that it can be removed from an internal working area 1114 (such as from a deck or a passageway). Optionally, although not required, the arms 1110 may be extendable and retractable, allowing them to move the lifted mobile robot 1112 back onto the base / support surface 1108.

[0077] As shown in the figure, the facility 100 is generally intended to have a barrier 1116 that separates at least a portion of the internal work area 1114 from the external area 1115, which may be frequently accessed by individuals / operators. In other words, generally, the mobile robot 1112 moves within the internal work area 1114, while the individual moves within the external area 1115. The barrier 1116 (such as a wall or fence) prevents the mobile robot 1112 from leaving the internal work area 1114. The barrier 1116 includes a number of slots (or cuts) 1118 (preferably two slots 1118) corresponding to the number of arms 1110.

[0078] Figures 55-57 The diagram illustrates several stages of the operation of the mobile robot station 1102 when retrieving the mobile robot 1112 (or introducing a mobile robot into the inner working area 1114). Initially, the mobile robot 1112 moves and positions itself at the end of the inner working area 1114, adjacent to the slot 1118. The mobile robot station 1102 also moves and positions itself next to the slot 1118 but on the other side of the barrier 1116 (on the outer area side of the barrier 1116). Figure 55 The image shows a mobile robot station 1102 extending an arm 1110 through a slot 1118 and extending beneath the mobile robot 1112. Figure 56 The image shows the mobile robot station 1102 raising the mobile robot 1112 above the top of the barrier 1116 via the operation of the height adjustment component 1106. Figure 57The diagram shows mobile robot station 1102 moving back into outer area 1115 to allow mobile robot 1112 to cross barrier 1116 and move into outer area 1115. This general action can be reversed to introduce mobile robot 1112 from outer area 1115 into inner work area 1114. This method allows for the removal and introduction of mobile robots without any additional structures to inner work area 1114 or outer area 1115.

[0079] Figure 58 A process 1200 for receiving a mobile robot (or robot) from a work area using a mobile robot station (or robot platform) is shown. Generally, it is anticipated that the robot can be received from a deck area or from a passageway. Furthermore, it is generally anticipated that the robot station can be any mobile robot station and involves some or all of the components described above, such as, for example, mobile robot stations 212, 300, 400, 500, 604, 704, 802, 902, and 1002. Certain actions (such as...) are also generally anticipated. Figure 58 The actions indicated herein may be performed by or involve different participants / devices, such as, for example, operator action 1226, robot system action 1228, and sensor confirmation action 1230.

[0080] At box 1202, the operator requests the removal of the robot. Generally, some indication is expected that the robot needs repair, replacement, or routine maintenance. For example, this indication could involve robot sensor readings and communication from the robot itself to external / remote control circuitry. Alternatively, the external control circuitry may be monitoring the robot's sensor readings and can determine that the robot requires repair. As a further alternative, the robot may be determined to be malfunctioning, or it may be approaching a predetermined time since the last repair or maintenance. The phrase "control circuitry" has been discussed above, and in one form, the external / remote control circuitry is expected to be a centralized control circuitry located remotely from the robot. Furthermore, the centralized control circuitry is expected to generally communicate with the individual robots.

[0081] At frame 1204, the first door inside the robot station opens. Figure 58 In this context, the action is shown to be performed by an operator, but it is also considered that in some forms, the action could be performed automatically (such as in response to a proximity sensor). As mentioned above, it is anticipated that when the inner (first) door is in the open position, the outer (second) door is prevented from moving to the open position.

[0082] At box 1206, a routing system (such as a navigation and / or communication system) routes the robot to the robot station. In some forms, the robot is expected to be externally controlled and instructed to proceed to the robot station. In other forms, the robot is expected to autonomously navigate to the robot station using an internal routing system.

[0083] At box 1208, the robot's position within the robot station is confirmed when the robot arrives at the station. In one form, the robot station is expected to include sensors configured to detect the robot's presence within the mobile robot station. Any variety of sensors can be used, including, for example, weight sensors, proximity sensors, pressure sensors, motion detectors / sensors, position sensors, etc. Depending on the type of sensor, it can be located at the robot station or it can be positioned at a remote location. These sensors can be coupled to or coordinated with internal (first) and external (second) doors to trigger their opening and closing based on the robot's position.

[0084] Additionally or alternatively, in some forms, it is anticipated that external / remote control circuitry can confirm or receive confirmation of the robot's position within the robot station. In one form, the control circuitry can confirm or receive confirmation that the robot is correctly received within the robot station via position data. This position confirmation can be accomplished in various ways. For example, position data can be obtained from the robot's motor encoder, which can be used to confirm its position relative to an observed robot reference marker. Furthermore, the mobile robot can use its RFID reader, camera, and / or other devices to establish its position as an alternative or additional level of position confirmation.

[0085] At box 1210, after the robot has been properly received in the robot station, the inner (first) door is closed. In some configurations, both the inner (first) door and the outer (second) door will be in the closed position. At box 1212, the operator manually shuts down the robot, such as by manually triggering a switch on the robot's access panel. However, in other configurations, it is expected that the robot can be deactivated automatically, or that remote control circuitry can instruct the robot to deactivate automatically.

[0086] At box 1214, the operator can dock the maintenance cart to the robotic station, preferably near the external (second) door. As an example, any of the various maintenance carts described above can be used, and it is generally expected that the cart will be docked so that the robot can easily move from the robotic station to the cart. At box 1216, sensors are preferably used to confirm that the internal (first) door is closed (and optionally to confirm that the cart has been correctly docked). Any of the various sensors and / or positioning methods described above can be used.

[0087] At box 1218, the outer (second) door of the robot station is unlocked. Generally, some mechanical or control circuitry / software mechanism, such as those described above, is intended to lock the outer (second) door and prevent it from opening when the inner (first) door is in the open position. Now, this mechanism no longer prevents the outer (second) door from opening when the inner (first) door is in the closed position. At box 1220, the operator opens the outer (second) door. Alternatively, in other forms, the opening of the outer (second) door is expected to be triggered, such as by a sensor and / or by instructions from the control circuitry.

[0088] At box 1222, the operator manually rolls (or otherwise moves) the robot onto the cart. In one configuration, the operator is expected to attach a brake box to the robot and then manually roll the robot onto the cart. At box 1224, after the robot has been moved to the cart, the operator can close the external (second) door and remove the cart from the robot station. The operator can then move the cart with the robot on it to a maintenance or service area.

[0089] Figure 59 The diagram illustrates a process 1300 for introducing (or importing) a mobile robot (or robot) into a work area using a mobile robot station (or robot platform). Generally, it is anticipated that the robot can be introduced from a safe, external area where individuals are present and the robot is not operating. Generally, it is anticipated that the robot can be introduced into a deck area or aisle of the work area where the robot is operating.

[0090] Many actions are similar to those described above in conjunction with robot removal process 1200, but performed in reverse order. The description of process 1200 is largely incorporated herein, and process 1300 can be modified in a manner consistent with it. Again, it is generally expected that the robot station can be any mobile robot station and involves some or all of the components described above, such as, for example, mobile robot stations 212, 300, 400, 500, 604, 704, 802, 902, and 1002. Furthermore, certain actions, such as... Figure 59 As indicated in the document, actions can be performed by or involve different participants / devices, such as operator action 1326, robot system action 1328, and sensor confirmation action 1330.

[0091] At box 1302, the operator can dock a maintenance trolley carrying the robot to the robot station, preferably adjacent to the outer (second) door. As an example, any of the various maintenance trolleys described above can be used, and it is generally expected that the trolley will be docked so that the robot can be easily transferred from the robot station to the trolley. In other words, the operator transports the robot (preferably deactivated) to the robot station located near the edge of the passageway or deck. At box 1304, the operator opens the outer (second) door. As mentioned above, it is expected that when the outer (second) door is in the open position, the inner (first) door is prevented from moving to the open position. Alternatively, in other forms, it is expected that the opening of the outer (second) door can be triggered, such as by a sensor and / or by instructions from control circuitry.

[0092] At box 1306, the operator manually rolls (or otherwise moves) the robot from the trolley into the robot station. In other words, the operator moves the robot through the open external (second) door of the robot station and onto the base of the robot station, the external (second) door being movable between an open and closed position. In one form, the operator is expected to use a brake box to manually move the robot onto the trolley.

[0093] At box 1308, after the robot has been moved into the robot station, the operator can close the external (second) door. Alternatively, in other forms, the closing of the external (second) door is expected to be triggered, such as by a sensor and / or by instructions from control circuitry. In some forms, both the internal (first) door and the external (second) door will be in the closed position. In some forms, the robot is expected to be charged in the station before being introduced into the work area. At box 1310, the operator manually starts the robot, such as by manually triggering a switch on the robot's access panel. However, in other forms, remote control circuitry is expected to activate or power the robot.

[0094] At box 1312, the robot's position within the robot station is confirmed. As described above, in one form, the robot station is expected to include sensors configured to detect the robot's position within the mobile robot station, and any various types of sensors can be used. These sensors may be coupled to or coordinated with internal (first) and external (second) gates. Additionally or alternatively, in some forms, external / remote control circuitry is expected to confirm or receive confirmation of the robot's position within the robot station. In one form, control circuitry may confirm or receive confirmation that the robot is correctly positioned within the robot station via position data, and this positioning confirmation may be performed in various ways, as described above.

[0095] At frame 1314, the internal (first) door of the robot station is open, and the internal (first) door can move between an open position and a closed position. Figure 59 In this context, the action is shown as being performed by an operator, but it is also contemplated that in some forms, the action could be performed automatically (e.g., in response to sensors and / or control circuitry). Generally, it is anticipated that the inner (first) door provides the robot with access to a passageway or deck to allow the robot to move along it. As mentioned above, it is anticipated that when the inner (first) door is in the open position, the outer (second) door is prevented from moving to the open position. In other words, when one of the outer and inner doors is in the open position, the other of the outer and inner doors is preferably prevented from moving to the open position. At box 1316, the operator can request permission to introduce (or import) the robot into the work area.

[0096] At box 1318, the opening of the internal (first) door is confirmed. In some forms, sensors are expected to be coupled to or coordinated with the internal (first) door to confirm its open position. At box 1320, the routing system routes the robot to the desired location within the facility. In some forms, the robot is expected to be externally controlled and instructed to proceed to the robot station. In other forms, the robot is expected to autonomously navigate to the robot station using the internal routing system. At box 1322, the operator closes the internal (first) door and removes the cart from the robot station.

[0097] Generally, the aforementioned mobile robot stations and processes are designed to ensure the safety of individuals within the facility. For example, in some forms, it is anticipated that safety sensors can be used to initiate an emergency stop on the entire system (or a portion thereof) if a door is detected to be in an incorrect position. An internal (first) door may include a safety sensor to detect the state / position of the internal door, and an external (second) door may also include a safety sensor to detect the state / position of the external door. Both safety sensors can, in turn, be coupled to a safety programmable logic controller (PLC). If the safety PLC determines that either of the two safety sensors indicates an incorrect and / or unsafe position for either door, it can initiate an emergency stop on the system.

[0098] Figures 60-65 Another example of a mobile robot receiving system 1400 and a mobile robot station 1402 is shown in general. The mobile robot station 1402 is generally intended to be used to isolate and remove mobile robots that may be damaged or require some form of maintenance. However, it is also contemplated that the system 1400 may involve additional capabilities, such as acting as a picking, distributing, and / or decanting workstation, in which products and / or containers (such as bins) can be removed from or stored at the mobile robot. This example of the mobile robot station 1402 could serve as a general-purpose workstation with a variety of potential uses. The mobile robot station 1402 is generally intended to utilize one or more components of the previously described mobile robot station, unless inconsistent therewith.

[0099] In one form, the mobile robot station 1402 includes at least one door (and preferably two doors) in the form of a pivotable / hinged cover (or clamshell structure). In some forms, the door can pivot about an axis / hinge between an open position and a closed position. In some forms, the door can pivot about one or more pivot axes. In some forms, the door may be spring-loaded or counterweighted to facilitate movement between the open and closed positions. It is also contemplated that the door can be latched or locked into place after pivoting to the open or closed position, such as manually or via control circuitry.

[0100] The mobile robot station 1402 includes a first door 1404 located at (and defining) an entrance 1405 of the mobile robot station 1402. The first door 1404 can be accessed by a mobile robot 1406 moving along a passageway or deck 1416. The first door 1404 is movable between a first position and a second position, such that the mobile robot 1406 can enter or exit the mobile robot station 1402 via the entrance 1405 when in the first position, and such that the mobile robot 1406 is prevented from entering or exiting the mobile robot station 1402 via the entrance 1405 when in the second position.

[0101] The mobile robot station 1402 also preferably includes a second door 1410, which is movable between an open position and a closed position. The second door 1410 is located at (and defines) the exit 1411 of the mobile robot station 1402. The second door 1410 is movable between a third position and a fourth position, such that the mobile robot 1406 can be moved into or out of the mobile robot station 1402 via the exit 1411 when in the third position, and such that the mobile robot 1406 cannot be moved into or out of the mobile robot station 1402 via the exit 1411 when in the fourth position.

[0102] Figures 60-63 The mobile robot station 1402 is shown in three different states. Figure 60 and Figure 63 The first state is shown, in which mobile robot 1406 can move to mobile robot station 1402 through inlet 1405. Figure 60 and 63In this configuration, the first door 1404 is in the first position, and the second door 1410 is in the fourth position. In this orientation, the mobile robot 1406 can enter the mobile robot station 1402 through the entrance 1405 but cannot exit by any other means. Furthermore, user access to the volume of the mobile robot station 1402 is blocked, preventing the user from inserting items into or removing items from the container carried by the mobile robot 1406 within the mobile robot station 1402. In one embodiment, in this first state, the first door 1404 acts as a cover to block user access.

[0103] Figure 61 The mobile robot station 1402 is shown in its second state. As can be seen, in this second state, the first door 1404 (which may be in the form of a first covering portion) has pivoted about axis 1412 to block the entrance and confine the mobile robot 1406 within the mobile robot station 1402. This second state also prevents other mobile robots 1406 from entering the station 1402. Figure 61 In this configuration, the first door 1404 is now in the second position, but the second door 1410 remains in the fourth position. When the first door 1404 is in this second position, it provides a user with access to the volume of the mobile robot station 1402, allowing the user to insert items into and remove items from a container carried by the mobile robot 1406 within the mobile robot station 1402 (or to insert and remove the container itself). In other words, the first door 1404 (which may include a first covering portion) is configured to selectively allow and block access to the container carried by the mobile robot 1406 when the mobile robot 1406 is in the mobile robot station 1402.

[0104] With the second door 1410 still in the fourth position, a wall / barrier 1414 is expected to remain between the mobile robot 1406 and the user in station 1402. As can be seen, in this form, the wall / barrier 1414 generally surrounds the mobile robot 1406 on three sides (and the first door 1404 blocks the entrance on the fourth side). This barrier 1414 provides safety and protection for the user in this second state. Additional mobile robot features can be used to ensure user safety, such as, for example, requiring a pinion to extend and engage with certain structures of the mobile robot station 1402. In one form, the mobile robot station 1402 can function as a workstation where items in a container (or bin), or the container itself, are transferred to or from the mobile robot 1406 occupying station 1402. For example, the user can perform operations such as picking or distributing individual items from a container or emptying items into a container or bagging a container.

[0105] Figure 62The mobile robot station 1402 is shown in its third state. As can be seen, in this third state, the second door 1410 (which may be in the form of a second cover portion) has pivoted about axis 1412, allowing user access to remove the mobile robot 1406 from the mobile robot station 1402. In one form, the first and second doors 1404, 1410 may pivot about the same axis 1412. Alternatively, in other forms, the first and second doors 1404, 1410 may be configured to pivot about different axes, rather than the same axis.

[0106] exist Figure 62 In this configuration, the first door 1404 remains in the second position, but the second door 1410 is now in the third position. When the second door 1410 is in this third position, the user can remove the mobile robot 1406 via exit 1411. In other words, the second door 1410 (which may include a second covering portion) is configured to selectively expose and block exit 1411 of the mobile robot station 1402. In some forms, it may be desirable for the mobile robot station 1402 to be deactivated before allowing the mobile robot station 1402 to transition to this third state, i.e., before pivoting the second door 1410 from the fourth position to the third position. For example, a programmable logic controller (PLC) can be used to prevent the pivoting of the second door 1410 until the mobile robot 1406 has been deactivated. Generally, some form of interlocking safety device can be used to control access to perform certain actions, such as removing the mobile robot 1406. Furthermore, it may be desirable to provide only authorized technicians with permission to remove the mobile robot 1406. Alternatively, it should also be understood that when the mobile robot station 1402 is in this third state, the mobile robot 1406 can be brought in (or introduced) via exit 1411.

[0107] In some forms, such as Figures 60-65 As shown, the first and second doors 1404, 1410 may include first and second covering portions, such that one is nested within the other (forming a double clamshell). In one nesting configuration, for example, the second door 1410 cannot be moved unless the first door 1404 has pivoted from the first position to the second position. Alternatively, in other configurations, the first and second doors 1404, 1410 may be configured such that they can move independently of each other. Furthermore, in some configurations, it is anticipated that doors 1404, 1410 can be moved manually and / or may involve the use of sensor 222 and / or control circuitry 224, as described above.

[0108] Figures 63-65 Additional views of the mobile robot receiving system 1400 and the mobile robot station 1402 are shown. Figure 63The image shows a mobile robot station 1402 in a first state, with entrance 1405 open. The mobile robot station 1402 may include a bridge or arch structure 1415 that defines entrance 1405, which pivots as part of a first door 1404 or about which the first door 1404 pivots. Figure 64 The image shows a mobile robot station 1402A in the first state, next to another mobile robot station 1402B in the third state. Figure 65 The image shows a mobile robot station 1402C in the first state, next to another mobile robot station 1402D in the second state.

[0109] As can be seen, the mobile robot station 1402 may be positioned at or near the edge of deck 1416 (or transfer area / plane). In some forms, the mobile robot station 1402 may be positioned near the end of deck 1416, or deck 1416 may be further extended to accommodate the mobile robot station 1402. For example, an extension area 1417 may extend alongside deck 1416 along the X direction and may consist of one or more panels. The extension area 1417 may include horizontal tracks in station 1402 for efficient access to and from station 1402 via deck 1416.

[0110] Figure 66 and 67 This illustrates how mobile robot stations 1402 can be positioned outside the general traffic flow of mobile robots 1406 at facility 1422. It is anticipated that mobile robot 1406 can move along horizontal aisle 1418 to vertical aisle 1420 and then descend to deck 1416. Two mobile robot stations 1402 can be located at the edge of deck 1416 such that they are substantially outside the traffic flow of mobile robots 1406 using deck 1416. In one form, as... Figure 67 As indicated by the arrows, mobile robots 1406 can travel in approximately the same direction along the horizontal aisle 1418 at different levels, and can then merge from their respective levels and travel down the vertical aisle 1420 to different levels, where they can each enter and occupy a mobile robot station 1402. If mobile robots 1406 are performing picking, distributing, or unpacking operations and need to remain active in the system, they can then move back out through the entrance and proceed in the opposite direction to where they approached the mobile robot station 1402. This general traffic flow of mobile robots 1406 helps to avoid traffic congestion.

[0111] Figure 68 and 69An example is shown showing how mobile robot station 1402 can be strategically positioned in a desired location around facility 1422. Figure 68 Two sets of mobile robot stations 1402 are shown positioned at opposite ends of deck 1416A to mitigate mobile robot traffic congestion. The mobile robot stations 1402 can be positioned at the ends of workstation deck 1416A such that they are largely outside the regular traffic flow of mobile robots 1406. Figure 68 As can be seen, on each work station deck 1416A, there are four mobile robot stations 1402, with two stations 1402 in each group located at one end of deck 1416A. Other decks may be fast decks 1416B, without mobile robot stations 1402, allowing mobile robots 1406 to move between aisles 1424 and to be strategically distributed at facility 1422. As can be seen, two work station decks 1416A are interrupted in the middle to make room for the mobile robot stations 1402 (in contrast to the uninterrupted fast deck 1416B).

[0112] Figure 69 This illustrates how mobile robot station 1402 can be set up on different levels of facility 1422. Mobile robot station 1402 can be used for various purposes. It should be understood that mobile robot station 1402 can be used solely as a removal / introduction station, solely as a box-turning / distribution / picking station, or as a general-purpose station allowing both removal / introduction and box-turning / distribution / picking. Figure 69 The diagram generally shows mobile robot stations 1402 organized in pairs around facility 1422; however, it should be understood that other arrangements are possible. The specific purpose of the mobile robot stations 1402 can help determine their location within facility 1422. For example, it may be desirable to distribute products or containers on the first floor of facility 1422, such as after goods have arrived, so some or all of the mobile robot stations 1402 on the first floor could be dedicated to distributing products or containers to mobile robots 1406.

[0113] Figure 70 A process 1500 for receiving a mobile robot from a work area using a mobile robot station is shown. The mobile robot is expected to participate in picking / distribution / unpacking operations at the station, in which items or containers are removed from or stored at the mobile robot. Alternatively, the station is expected to be used to safely remove the mobile robot from the work area. Furthermore, the mobile robot station is generally expected to involve some or all of the components of mobile robot station 1402, and the above description of mobile robot station 1402 is incorporated herein.

[0114] At box 1502, the mobile robot enters the mobile robot station via the station's entrance. In process 1500, in one form, the mobile robot station is expected to include two doors, with the first door in a first position and the second door in the aforementioned fourth position. In this state, the only generally expected open area is the station's entrance. Furthermore, in this state, the mobile robot can perform several operations that do not involve picking / distributing / unloading or secure removal within the station, such as using the station for recharging and / or using it as a parking area outside the general traffic flow of mobile robots in the work area. After performing these other operations, the mobile robot can leave the station at some point via the entrance.

[0115] At box 1504, the mobile robot is deactivated. In one form, the mobile robot may be deactivated as a safety measure before picking / distributing / unloading operations or before controlled removal of the mobile robot itself from the station and work area via the station's exit. Generally, this deactivation step is expected to occur at various stages of process 1500. For example, in one form, the deactivation step may be performed later in process 1500 after the user has access to the mobile robot from above and can manually deactivate it. In other forms, remote deactivation may be possible, such as via control circuitry to the mobile robot.

[0116] At box 1506, assuming a picking / distribution / box-turning operation or a mobile robot removal operation is about to be performed, the first door is moved to the position of the entrance to the barrier station. Generally, the first door is expected to include a first covering portion, and the first door can pivot from the first position to the aforementioned second position. In this state, the first and second doors are expected to together define a four-walled barrier surrounding the mobile robot, but the mobile robot station is open to allow user access.

[0117] At box 1508, a user can pick, distribute, or unload items and / or containers. For example, a user can pick items from bins or other containers transported by the mobile robot (or can pick the bins or containers themselves). Additionally, or as an alternative example, a user can store items in bins or other containers transported by the mobile robot (or can store the bins or containers themselves with the mobile robot). It should be understood that this is an optional step. If the sole purpose of using the station is to safely remove the mobile robot from the work area or for temporary parking or recharging, this step need not be performed.

[0118] At box 1510, assuming the picking / distribution / box-turning operation has been performed and completed, the mobile robot can be reactivated. This step can be performed at various stages of the process. In one form, the mobile robot station is expected to be open, and the user manually reactivates the mobile robot. In other forms, remote reactivation via control circuitry may be possible.

[0119] At box 1512, the mobile robot recharges in the station. While this recharging can be performed at various stages of the process, in one form, it can be performed after reactivation following the completion of picking / distribution / box-turning operations. Additionally, at box 1514, the first door can be moved back from the second position to the first position, which again covers the station but also opens the station's entrance. The mobile robot can then exit through the station's entrance.

[0120] At boxes 1516 and 1518, a mobile robot removal operation (instead of picking / distributing / emptying boxes) is expected to be performed. In this configuration, boxes 1508-1512 may have been skipped. At box 1516, the second door is moved to expose the exit. In one configuration, the second door pivots from a fourth position (blocking the exit) to a third position (exposing the exit), as described above. At box 1518, the user removes the mobile robot. In some configurations, it is expected that only authorized users / technicians will perform this removal, and / or the second door may be immovable unless the mobile robot is deactivated. After the mobile robot is removed, the first and second doors can be moved back to their original positions, allowing the entrance to open and another mobile robot to use the station.

[0121] Those skilled in the art will recognize that various other modifications, alterations, and combinations can be made to the embodiments described above without departing from the scope of the invention, and such modifications, alterations, and combinations will be considered to fall within the scope of the inventive concept.

Claims

1. A mobile robot receiving system, comprising: A passageway or deck configured to facilitate the movement of a mobile robot along the passageway or deck; A mobile robot station, located adjacent to the edge of the passageway or the deck, the mobile robot station comprising: A first door is located at the entrance of the mobile robot station and can be accessed by a mobile robot moving along the passage or the deck. The first door is movable between a first position and a second position, wherein the mobile robot can move into or out of the mobile robot station via the entrance when in the first position, and wherein the mobile robot is prevented from moving into or out of the mobile robot station via the entrance when in the second position.

2. The mobile robot receiving system of claim 1, wherein the mobile robot station comprises: A second door is located at the exit of the mobile robot station. The second door is movable between a third position and a fourth position, wherein the mobile robot can be moved into or out of the mobile robot station via the exit when it is in the third position, and wherein the mobile robot cannot be moved into or out of the mobile robot station via the exit when it is in the fourth position.

3. The mobile robot receiving system of claim 2, wherein the first gate and the second gate are configured such that: When the second door is in the third position, the first door is prevented from moving to the first position; and When the first door is in the first position, the second door is prevented from moving to the third position.

4. The mobile robot receiving system of claim 2, wherein: The mobile robot station further includes a pole; The first door includes a first panel configured to move vertically between an upward position and a downward position; The second door includes a second panel configured to move vertically between an upward position and a downward position; and The rod is configured to move horizontally between a first setting and a second setting, wherein the rod blocks vertical movement of the first plate in the first setting and blocks vertical movement of the second plate in the second setting.

5. The mobile robot receiving system of claim 2, wherein the mobile robot station further comprises a rotating cover, the rotating cover comprising a first portion rotatable to open and close the first door, and a second portion rotatable to open and close the second door.

6. The mobile robot receiving system of claim 1, wherein the mobile robot station further comprises: A motion system configured to facilitate docking of the mobile robotic station with the edge of the passageway or the deck to position the mobile robotic station in a docking position; A first blocking portion and a second blocking portion, the first and second blocking portions being configured to extend across the passage or the deck when the mobile robot station is in the docking position; as well as A track ramp is configured to allow the mobile robot to move along the base of the mobile robot station.

7. The mobile robot receiving system of claim 2, further comprising a maintenance trolley disposed adjacent to the second door of the mobile robot station, the maintenance trolley being configured to facilitate the transfer of the mobile robot from the mobile robot station to the maintenance trolley.

8. The mobile robot receiving system of claim 2, further comprising control circuitry operatively coupled to the first gate and the second gate, the control circuitry being configured to restrict movement of the first gate when the second gate is in the third position, and to restrict movement of the second gate when the first gate is in the first position.

9. The mobile robot receiving system of claim 1, wherein, When the first door is in the second position, the user's access to the volume of the mobile robot station is provided, allowing the user to insert items into and remove items from a container carried by the mobile robot within the mobile robot station.

10. The mobile robot receiving system of claim 9, wherein, When the first door is in the first position, the user's access to the volume of the mobile robot station is blocked, preventing the user from inserting items into the container carried by the mobile robot within the mobile robot station and from removing items from the container.

11. The mobile robot receiving system of claim 2, wherein: The first door includes a first covering portion configured to selectively allow and block access to a container carried by the mobile robot when the mobile robot is in the mobile robot station; and The second door includes a second covering portion configured to selectively expose and block the exit of the mobile robot station.

12. The mobile robot receiving system of claim 11, wherein the mobile robot station is configured to occupy one of three states: In the first state, the mobile robot can move to the mobile robot station through the entrance; In the second state, the first covered portion of the mobile robot station has been pivoted about the axis to block the entrance and confine the mobile robot within the mobile robot station; as well as In the third state, the second covering portion has been pivoted about the axis, thereby allowing user access to remove the mobile robot from the mobile robot station.

13. The mobile robot receiving system of claim 1, further comprising: A robot blocker, configured in conjunction with a channel, allows a mobile robot to move along the track structure. The robot blocker can move between a blocking position and a non-blocking position that restricts the mobile robot from entering or leaving the mobile robot station. as well as The rollers on the first door move the robot blocker from the blocking position to the unblocking position as the first door moves from the second position to the first position.

14. The mobile robot receiving system of claim 1, further comprising: A robot blocker, configured in conjunction with a channel, allows a mobile robot to move along the track structure. The robot blocker can move between a blocking position and a non-blocking position that restricts the mobile robot from entering or leaving the mobile robot station. as well as A support surface for a mobile robot includes a protrusion configured to be mounted to the mobile robot station and, upon mounting, cause the robot blocker to move from a blocking position to a non-blocking position.

15. The mobile robot receiving system of claim 1, further comprising: The entry port is located in the mobile robot station; as well as An access port cover is movable between an open position and a closed position, in which the access port is uncovered and in the closed position the access port is covered. The first door can only be moved to the first position when the access port cover is in the closed position.

16. A method for receiving a mobile robot, comprising: To move the mobile robot along the passage or deck toward a mobile robot station adjacent to the edge of the passage or deck; The first door is movable and received by the mobile robot through the entrance of the mobile robot station and by the mobile robot that can move along the passage or the deck. The first door is movable between a first position and a second position, wherein the mobile robot can move into or out of the mobile robot station via the entrance when it is in the first position, and wherein the mobile robot is prevented from moving into or out of the mobile robot station via the entrance when it is in the second position.

17. The method of claim 16, further comprising: The mobile robot is moved through a second door at an exit of the mobile robot station, the second door being movable between a third position and a fourth position, wherein the mobile robot can be moved into or out of the mobile robot station via the exit when it is in the third position, and wherein the mobile robot cannot be moved into or out of the mobile robot station via the exit when it is in the fourth position.

18. The method of claim 17, further comprising: When the second door is in the third position, it prevents the first door from moving to the first position; as well as When the first door is in the first position, it prevents the second door from moving to the third position.

19. The method of claim 16, further comprising: When the first door is in the second position, it provides the user with access to the volume of the mobile robot station, allowing the user to insert items into and remove items from containers carried by the mobile robot within the mobile robot station.

20. The method of claim 19, further comprising: When the first door is in the first position, it prevents the user from accessing the volume of the mobile robot station, so that the user cannot insert items into the container carried by the mobile robot in the mobile robot station or remove items from the container.

21. The method of claim 17, further comprising: After the mobile robot has been received at the mobile robot station, the power supply to the mobile robot is deactivated.

22. The method of claim 21, further comprising: The maintenance trolley is docked to the mobile robot station near the second gate; as well as The deactivated mobile robot is moved through the second door in the third position onto the maintenance cart.

23. A method for receiving a mobile robot, comprising: Transport decommissioned mobile robots toward mobile robot stations located near the edge of adjacent passageways or decks; The mobile robot is moved to the base of the mobile robot station through the open outer door of the mobile robot station, and the outer door can move between an open position and a closed position; The external doors are shut off and power is supplied to the mobile robot; as well as The internal door of the mobile robot station is opened and is movable between an open and closed position, providing the mobile robot with access to the passageway or the deck to allow the mobile robot to move along the passageway or the deck; When one of the outer and inner doors is in the open position, the other of the outer and inner doors is prevented from moving to the open position.

Images