Automated storage and retrieval system

Abstract

Various embodiments of the present disclosure provide an automated storage and retrieval system.

Description

Automated Storage and Retrieval SystemPriority

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 452,625, filed March 16, 2023, U.S. Provisional Application No. 63 / 452,672, filed March 16, 2023, and U.S. Provisional Application No. 63 / 452,677, filed March 16, 2023, the entire contents of each are incorporated by reference herein.Field

[0002] The present disclosure relates to automated storage and retrieval systems that use automated vehicles to store containers filled with items on a rack and, afterwards, to retrieve the containers.Background

[0003] Warehousing and distribution facilities have grown in importance. These facilities receive many types of items and store them until a later time at which the items are shipped elsewhere, such as to consumers' homes or to retail stores. Some of these facilities store hundreds, thousands, or even tens of thousands of unique items in different containers, such as bins. These containers are typically stored on storage racks to maximize the use of vertical space. To increase efficiency, many of these facilities have installed one of many types of automated storage and retrieval systems that use warehouse-management software to keep track of the items and their locations and that use automated vehicles to store the containers in and retrieve the containers from the storage racks.Summary

[0004] Various embodiments of the present disclosure provide an automated storage and retrieval system including a storage rack, multiple containers, multiple vehicles, and a control system. The storage rack supports multiple position identifiers each associatedwith a unique position, and each container includes a container identifier that uniquely identifies that container. The vehicle includes a first sensor configured to read the position identifiers and a second sensor configured to read the container identifiers. Feedback from the first sensor reading the position identifiers enables the control system to determine the position of the vehicle beneath the storage rack and, by extension, whether the vehicle is positioned beneath a desired storage area for a loading or unloading process. Feedback from the second sensor reading the container identifier of a container loaded onto the vehicle enables the control system to determine whether the vehicle is carrying a desired container.

[0005] Various embodiments of the present disclosure provide an automated vehicle for an automated storage and retrieval system. The vehicle includes a chassis and a container support configured to support a container. The container support is movable relative to the chassis in a in a first direction (such as a vertical direction) and in a second direction transverse to the first direction (such as a horizontal direction). The ability of the container support to move relative to the chassis in these two directions enables the container support to move the container to store a container in and / or retrieve a container from a storage rack while the chassis remains stationary.

[0006] Various embodiments of the present disclosure provide an automated storage and retrieval system including a storage rack, multiple containers, multiple vehicles, and a control system. The storage rack includes one or more container supports configured to, when engaged by rack engagers of a container as the vehicle lowers the container into a storage area of the storage rack, guide the container to a storage position.Brief Description of the Figures

[0007] Figure 1 A is a perspective view of a storage rack, multiple containers, and a vehicle of one example embodiment of an automated storage and retrieval system of the present disclosure.

[0008] Figure IB is a block diagram of an ASRS control system and the vehicles of the automated storage and retrieval system of Figure 1A.

[0009] Figure 2 is a perspective view of the storage rack of the automated storage and retrieval system of Figure 1 A.

[0010] Figure 3 is a perspective view of part of the storage rack of Figure 2.

[0011] Figure 4 is a top plan view of the storage rack of Figure 2.

[0012] Figure 5 is a bottom plan view of the storage rack of Figure 2 showing example position identifiers on the underside of the storage rack.

[0013] Figure 6 is similar to Figure 4, but shows a container stored in each storage area of the storage rack.

[0014] Figure 7 is a side elevational view of the storage rack of Figure 2 showing a container stored in one of the storage areas of the storage rack.

[0015] Figures 8A and 8B are perspective views of a container support of the storage rack of Figure 2.

[0016] Figure 8C is a front elevational view of the container support of Figure 8A.

[0017] Figure 9A is a top perspective view of a container of the automated storage and retrieval system of Figure 1 A.

[0018] Figure 9B is a bottom perspective view of the container of Figure 9A along with a cutaway showing the container identifier of the container.

[0019] Figure 9C is a side elevational view of the container of Figure 9A.

[0020] Figure 9D is a front elevational view of the container of Figure 9A.

[0021] Figure 9E is a perspective view of one of the rack engagers of the container of Figure 9A.

[0022] Figure 10A is a top perspective view of one example embodiment of an automated vehicle of the present disclosure with a container support of a support assembly of the automated vehicle in a home position and a lower position.

[0023] Figure 10B is similar to Figure 10A but shows the container support in an offset position and an upper position.

[0024] Figures 11 A and 11B correspond to Figures 10 A and 10B, respectively, and show the container support supporting a container.

[0025] Figures 12A and 12B are side elevational views corresponding to Figures 10A and 10B, respectively.

[0026] Figure 13 is a bottom perspective view of the automated vehicle of Figure 10A with the container support in the home position and the lower position.

[0027] Figure 14 is a top perspective view of the support frame of the support assembly of the automated vehicle of Figure 10A.

[0028] Figures 15 and 16 are top perspective and top plan views, respectively, of the container support of the support assembly of the automated vehicle of Figure 10A.

[0029] Figure 17 is a perspective view showing part of the mounting arrangement of the container support of Figures 15 and 16 to the support frame of Figure 14.

[0030] Figure 18 is perspective view of part of the storage rack of Figure 2 and the vehicle of Figure 10A showing the first sensor of the vehicle reading one of the position identifiers on the underside of the storage rack.

[0031] Figures 19A-19E are side elevational views showing the vehicle of Figure 10A loading the container of Figure 9A onto the storage rack of Figure 2.

[0032] Figures 20A-20C are cross-sectional side elevational views showing the container of Figure 9A being guided into a storage position as it is lowered into engagement with two of the container supports of Figure 8A.Detailed Description

[0033] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and non-limiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connections of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as mounted, connected, etc., are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably mounted, connected, and like mounting methods. This specification is intended tobe taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

[0034] Figures 1 A-ll show one example embodiment of an automated storage and retrieval system 10 of the present disclosure ("ASRS" for short) and components thereof. The ASRS 10 includes a storage rack 100, multiple containers 200, multiple vehicles 300, and an ASRS control system C. Generally, in operation, the ASRS control system C communicates with the vehicles 300 over a communication network and controls the vehicles 300 to load containers 200 into and unload containers 200 from the storage rack 100 from below. The containers 200 are loaded (by a human or automated loader) with one or more items at suitable operator stations (not shown). Items from the containers 200 are also unloaded (by a human or automated unloader) at the operator stations. A coordinate system shown in several of the drawings, including Figure 1A, is used herein as a frame of reference for orientation and directional movement of various components of the ASRS 10 in the X-, Y-, and Z-directions (which are perpendicular to one another in this example embodiment).

[0035] The storage rack 100, best shown in Figures 2-7, acts as a storage location for the containers 200. The storage rack 100 includes first, second, third, fourth, fifth, sixth, seventh, and eighth legs 110a, 110b, 110c, llOd, IlOe, 11 Of, 110g, and 11 Oh supporting a grid formed by a first set of rails 120a-120d and a second set of rails 130a-1301. The second set of rails of the grid support multiple container supports 140a-140x configured to, as described below, support the containers 200 and guide the containers 200 into storage positions as they are lowered onto the container supports.

[0036] The legs HOa-llOh are oriented substantially upright in the Z-direction. The rails 120a-120d of the first set of rails are supported by and extend substantially perpendicular to the legs HOa-llOh in the X-direction. Specifically, the rail 120a extends between the first and fifth legs 110a and IlOe in the X-direction and is supported by and connects them. The rail 120b extends between the second and sixth legs 110b and IlOf in the X-direction and is supported by and connects them. The rail 120c extends between the third and seventh legs 110c and 110g in the X-direction and is supported by and connects them. The rail 120d extends between the fourth and eighth legs llOd and IlOh in the X-direction and is supported by and connects them. The rails 130a-1301 of the second set of rails aresupported by and extend substantially perpendicular to the rails 120a-120d of the first set of rails. Specifically, the rails 130a-130d, which are spaced-apart in the X-direction, extend between the rails 120a and 120b in the Y-direction and connect them. The rails 130e-130h, which are spaced-apart in the X-direction, extend between the rails 120b and 120c in the Y- direction and connect them. The rails 130i— 1301, which are spaced-apart in the X-direction, extend between the rails 120c and 120d in the Y-direction and connect them. The legs and rails are mechanically connected to one another in any suitable manner, such as (but not limited to) via fasteners, keyhole fittings, or suitable brackets. The legs and rails may be formed from any suitable material, such as steel or aluminum.

[0037] As shown in Figures 5 and 11, certain of the rails support unique position identifiers 180 and 190. Each position identifier 180 and 190 is associated with unique data (such as an alphanumeric sequence) that itself represents a particular position, such as a position in the storage rack 100; a position in a particular direction (e.g., the X-direction or the Y-direction); and / or a position in the warehouse in which the storage rack 100 is installed. Accordingly, each unique position identifier 180 and 190 is associated with a unique position. Specifically, the position identifiers 180 are associated with positions in the X-direction, and the position identifiers 190 are associated with positions in the Y-direction. As explained in detail below, the vehicles 300 are configured to navigate to desired storage areas for loading or unloading a container 200 at least in part by reading the position identifiers 180 and / or 190.

[0038] In this example embodiment, each position identifier 180 and 190 includes a one-dimensional barcode. In other embodiments, certain or all of the position identifiers include three-dimensional barcodes, QR codes, or other optically readable indicia. In some embodiments, certain or all of the position identifiers include radio frequency identification (RFID) tags. In certain embodiments, certain or all of the position identifiers include near-field communication (NFC) tags. In various embodiments, certain or all of the position identifiers include Bluetooth beacons. In this example embodiment, the position identifiers 180 and 190 are located on the underside of certain of the rails. The position identifiers may be located in any other suitable location in other embodiments.

[0039] As best shown in Figures 4-6, the rails 120a-120d and 130a-1301 are positioned and oriented such that they define multiple -storage areas SA1-SA9, each ofwhich is sized and shaped to receive multiple containers 200 stacked atop one another. A first storage area SAI is defined between the rails 120a, 120b, 130a, and 130b. A second storage area SA2 is defined between the rails 120a, 120b, 130b, and 130c. A third storage area SA3 is defined between the rails 120a, 120b, 130c, and 130d. A fourth storage area SA4 is defined between the rails 120b, 120c, 130e, and 130f. A fifth storage area SA5 is defined between the rails 120b, 120c, 130f, and 130g. A sixth storage area SA6 is defined between the rails 120b, 120c, 130g, and 130h. A seventh storage area SA7 is defined between the rails 120c, 120d, 130i, and 130j. An eighth storage area SA8 is defined between the rails 120c, 120d, 130j, and 130k. An eighth storage area SA8 is defined between the rails 120c, 120d, 130j, and 130k. A ninth storage area SA9 is defined between the rails 120c, 120d, 130k, and 1301.

[0040] The first, fourth, and seventh storage areas SAI, SA4, and SA7 are substantially aligned in the Y-direction and form a first row of storage areas R1. The second, fifth, and eighth storage areas SA2, SA5, and SA8 are substantially aligned in the Y- direction and form a second row of storage areas R2. The third, sixth, and ninth storage areas SA3, SA6, and SA9 are substantially aligned in the Y-direction and form a third row of storage areas R3.

[0041] Each storage area SA has a width WSA extending in the X-direction. The width WSA is greater than the width Wc of the container 200 (described below). In this example embodiment, this size differential enables a vehicle 300 to raise and lower a container in the Z-direction between two adjacent rails when loading / unloading the container into / from a storage area SA without contacting the rails, as described below (though in other embodiments the container may contact part of the storage rack during raising / lowering). Additionally, each storage area SA has a depth DSA extending in the Y- direction. The depth DSA is greater than the depth De of the container 200. It is also large enough to enable a vehicle 300 to move a container in the Y-direction to clear the container supports when loading / unloading the container into / from a storage area SA without the container entering the adjacent storage area SA and contacting (and possibly dislodging) another container stored there, as described in detail below. As shown in Figure 7, the legs and rails are sized, shaped, positioned, oriented, and otherwise configured so the height H of the bottom of a container 200 above the floor FL in the Z-direction is greater than theheight of the top of a container on a container support of a container support of a vehicle 300 when the container support is in its lower position (described below). This enables the vehicle to travel beneath other storage areas SA while carrying a container without the container contacting (and possibly dislodging) other containers stored in the storage areas SA.

[0042] In this example embodiment, the storage areas all have the same width and depth. In other embodiments, the rails may define storage areas having two or more different sizes. For instance, certain rails may be spaced apart further than others, resulting in certain storage areas being wider and / or deeper than others. The rails may be positioned and repositioned relative to one another in any suitable manner to configure the storage rack to be used with any suitable quantity of differently sized containers.

[0043] Each storage area SA is associated with a set of four container supports 140 that are configured to guide the container into a storage position as the vehicle lowers the container into a storage area of the storage rack. As best shown in Figures 8A-8C, each container support 140 includes a body 141 and first and second rack-engager receivers 143 and 145 connected to the body 141. The body 141 includes rectangular first and second legs 141a and 141b oriented substantially parallel to one another and a connector 141c connecting the top ends of the first and second legs 141a and 141b such that the body 141 forms a U-shape. The first rack-engager receiver 143 includes a substantially horizontal support wall 143a, a first guide wall 143b extending upwardly and outwardly from one end of the support wall 143a, a second guide wall 143c extending upwardly and outwardly from the other end of the support wall 143a, and a third guide wall 143d between the first and second guide walls 143b and 143c and extending upwardly toward the first leg 141a. The support wall 143a and the first and second guide walls 143b and 143c form a substantially concave shape. First and second rack-engager-receiver supports 144a and 144b are connected to (and here are integrally formed with) the first leg 141a and support the first rack-engager receiver 143. The second rack-engager receiver 145 includes a substantially horizontal support wall 145a, a first guide wall 145b extending upwardly and outwardly from one end of the support wall 145a, a second guide wall 145c extending upwardly and outwardly from the other end of the support wall 145a, and a third guide wall 145d between the first and second guide walls 145b and 145c and extending upwardly towardthe second leg 141b. The support wall 145a and the first and second guide walls 145b and 145c form a substantially concave shape. First and second rack-engager-receiver supports 146a and 146b are connected to (and here are integrally formed with) the second leg 141b and support the second rack-engager receiver 145. In other embodiments, the container supports may take any other suitable shape and / or be fixed relative to the rails.

[0044] The container supports 140 are configured to be removably mounted to the rails 130a-130L As best shown in Figure 3, the body 141 is slid onto one of the rails 130 such that the underside of the connector 141c engages the top of the rail 130 and the first and second legs 141a and 141b are positioned across the opposing sides of the rail 130. When positioned in this way, the rack-engager receivers 143 and 145 extend into adjacent storage areas SA. Although not shown here, the container supports may be (temporarily) fixed in place on the rail in any suitable manner, such as via one or more fasteners.

[0045] Each storage area is associated with a set of rack-engager receivers of a set of container supports. Specifically, the first storage area SAI is associated with a first set of rack-engager receivers of a first set of container supports. The first set of container supports includes the container supports 140a-140d, and the rack-engager receivers include the second rack-engager receivers 145 of the container supports 140a and 140b and the first rack-engager receivers 143 of the container supports 140c and 140d. The second storage area SA2 is associated with a second set of rack-engager receivers of a second set of container supports. The second set of container supports includes the container supports 140c-140f, and the rack-engager receivers include the second rack-engager receivers 145 of the container supports 140c and 140d and the first rack-engager receivers 143 of the container supports 140e and 140f. The third storage area SA3 is associated with a third set of rackengager receivers of a third set of container supports. The third set of container supports includes the container supports 140e-140h, and the rack-engager receivers include the second rack-engager receivers 145 of the container supports 140e and 140f and the first rackengager receivers 143 of the container supports 140g and 140h.

[0046] As shown in Figure 4, the container supports 140a and 140b are spacedapart by the distance DRE (defined below), the container supports 140c and 140d are spacedapart by the distance DRE, the container supports 140e and 140f are spaced-apart by the distance DRE, and the container supports 140g and 140h are spaced-apart by the distanceDRE. The container supports 140a, 140c, 140e, and 140g are substantially aligned in the X- direction, and the container supports 140b, 140d, 140f, and 140h are substantially aligned in the X-direction.

[0047] The fourth storage area SA4 is associated with a fourth set of rackengager receivers of a fourth set of container supports. The fourth set of container supports includes the container supports 1401-1401, and the rack-engager receivers include the second rack-engager receivers 145 of the container supports 140i and 140j and the first rackengager receivers 143 of the container supports 140k and 1401. The container supports 140a and 140b are spaced-apart by the distance DRE (defined below), and the container supports 140c and 140d are spaced-apart by the distance DRE. The fifth storage area SA5 is associated with a fifth set of rack-engager receivers of a fifth set of container supports. The fifth set of container supports includes the container supports 140k-140n, and the rack-engager receivers include the second rack-engager receivers 145 of the container supports 140k and 1401 and the first rack -engager receivers 143 of the container supports 140m and 140n. The sixth storage area SA6 is associated with a sixth set of rack-engager receivers of a sixth set of container supports. The sixth set of container supports includes the container supports 140m-140p, and the rack-engager receivers include the second rack-engager receivers 145 of the container supports 140m and 140n and the first rack-engager receivers 143 of the container supports 140o and 140p.

[0048] The container supports 140i and 140j are spaced-apart by the distance DRE (defined below), the container supports 140k and 1401 are spaced-apart by the distance DRE, the container supports 140m and 140n are spaced-apart by the distance DRE, and the container supports 140o and 140p are spaced-apart by the distance DRE. The container supports 140i, 140k, 140m, and 140o are substantially aligned in the X-direction, and the container supports 140], 1401, 140n, and 140p are substantially aligned in the X-direction.

[0049] The seventh storage area SA7 is associated with a seventh set of rackengager receivers of a seventh set of container supports. The seventh set of container supports includes the container supports 140q-140t, and the rack-engager receivers include the second rack-engager receivers 145 of the container supports 140q and 140r and the first rack-engager receivers 143 of the container supports 140s and 140t. The eighth storage area SA8 is associated with an eighth set of rack -engager receivers of an eighth set of containersupports. The eighth set of container supports includes the container supports 140s-140v, and the rack-engager receivers include the second rack-engager receivers 145 of the container supports 140s and 140t and the first rack-engager receivers 143 of the container supports 140u and 140v. The ninth storage area SA9 is associated with a ninth set of rackengager receivers of a ninth set of container supports. The ninth set of container supports includes the container supports 140u-140x, and the rack-engager receivers include the second rack-engager receivers 145 of the container supports 140u and 140v and the first rack-engager receivers 143 of the container supports 140w and 140x.

[0050] The container supports 140q and 140r are spaced-apart by the distance DRE (defined below), the container supports 140s and 140t are spaced-apart by the distance DRE, the container supports 140u and 140v are spaced-apart by the distance DRE, and the container supports 140w and 140x are spaced-apart by the distance DRE. The container supports 140q, 140s, 140u, and 140 are substantially aligned in the X-direction, and the container supports 140r, 140t, 140v, and 140x are substantially aligned in the X-direction.

[0051] The storage rack 100 is merely one example storage rack that may be employed with the ASRS 10. Other storage racks may be configured differently, for instance with different quantities or types of legs, different quantities or types of rails, different quantities or types of dividers, different quantities or types of container supports and / or different quantities or types of container centerers. Storage racks may be sized and shaped for bespoke installations and may be configured to have any suitable quantity of storage areas.

[0052] The containers 200, one of which is shown in Figures 9A-9E, act as storage locations for items and are configured to be transported by the vehicles 300 and loaded / unloaded by the vehicles 300 into / from the storage rack 100. The container 200 includes a first side wall 212; a second side wall 214; a front wall 216; a back wall 218; a bottom wall 219; first, second, third, and fourth rack engagers 220, 230, 240, and 250; and a unique container identifier 280. As best shown in Figures 9C and 9D, the container 200 has a width Wc and a depth De, and the distance between the centers of the rack engagers is DRE.

[0053] The walls are connected to one another so the first and second side walls 212 and 214 are opposite one another; the front and back walls 216 and 218 are opposite one another, connect and extend between the first and second side walls 212 and 214, and aretransverse to the first and second side walls 212 and 214; and the bottom wall 219 is connected to the bottom edges of, extends between, and is transverse to the first and second side walls 212 and 214 and the front and back walls 216 and 218. The interior surfaces of these walls together define an item-storage area (not labeled) in which one or more items may be stored. The upper surfaces of the walls define an upper lip of the container 200. The walls of the container 200 are sized, shaped, positioned, oriented, and otherwise configured so multiples containers 200 can be stacked atop one another when stored in one of the storage areas SA of the storage rack 100.

[0054] The rack engagers 220, 230, 240, and 250 are sized, shaped, positioned, oriented, and otherwise configured to engage the set of container supports of a given storage area SA of the storage rack 100 when the container 200 is loaded into and stored in that storage area. The first and second rack engagers 220 and 230 are connected to (and in this example embodiment, integrally formed with) and extend outwardly from the first side wall 212, and the third and fourth rack engagers 240 and 250 are connected to (and in this example embodiment, integrally formed with) and extend outwardly from the second side wall 214.

[0055] The first rack engager 220 includes first, second, third, fourth, and fifth walls 221, 222, 223, 224, and 225 that together define a substantially convex engagement surface. The first and second walls 221 and 222 are spaced apart, substantially parallel, and substantially vertical. The third and fourth walls 223 and 224 extend downwardly and inwardly from the bottoms of the first and second walls 221 and 222, respectively. The fifth wall 225 is substantially horizontal and extends between and connects the third and fourth walls 224 and 225. The outer surfaces of these walls together define the substantially convex engagement surface. In this example embodiment, the engagement surfaces of all four of the rack engagers are convex surfaces, though in other embodiments only one, only two, or only three of the engagement surfaces are convex surfaces.

[0056] The container identifier 280 is associated with unique data (such as an alphanumeric sequence) that itself represents the unique container 200. Accordingly, each unique container identifier 280 is associated with a unique container 200. As explained in detail below, the vehicles 300 are configured to identify the containers 200 they are carrying or about to unload from the storage rack 100 by reading the container identifier 180. In thisexample embodiment, each container identifier 280 includes a QR code, as shown in Figure 9B. In other embodiments, the container identifier includes a one-dimensional barcode, a three-dimensional barcode, or another optically readable indicium. In some embodiments, the container identifier includes a radio frequency identification (RFID) tag. In certain embodiments, the container identifier includes a near-field communication (NFC) tag. In various embodiments, the container identifier includes a Bluetooth beacon. In this example embodiment, the container identifier 280 is located on the underside of the bottom wall 219 of the container 200. The container identifier may be located in any other suitable location in other embodiments.

[0057] This is merely one example of the container 200, and the container may have any other suitable configuration.

[0058] The vehicles 300 are configured to transport containers 200 to and from the storage rack, load the containers 200 into storage areas of the storage rack for storage, and unload the containers 200 from the storage areas of the storage rack. The vehicle 300 includes a chassis 1100, a mast 1200, a support assembly 1300 and associated first and second container-support actuators 1390a and 1390b, a first sensor 1370, a second sensor 1380, first and second drive wheels 1410 and 1420 and associated first and second drivewheel actuators 1410a and 1420a, a first pair of undriven wheels 1430 and 1440, a second pair of undriven wheels 1450 and 1460, a power source 1500, one or more navigation devices, a network interface, and a vehicle controller.

[0059] The chassis 1100 includes any suitable frame formed from any suitable components and configured to support the other components of the vehicle 300. The mast 1200 includes a support-assembly-mounting-rail support 1210 and a support-assembly mounting rail 1220. The support-assembly-mounting-rail support 1210 is connected to (such as via welding or via fasteners) and extends substantially vertically from the chassis 1100. The support-assembly mounting rail 1220 is connected to (such as via welding or via fasteners) the support-assembly-mounting-rail support 1210 and is oriented substantially vertically.

[0060] The support assembly 1300, which is best shown in Figures 14-17, is configured to support the container 200 and, under the control of the first and second container-support actuators 1390a and 1390b, move the container 200 in first and seconddirections (here, vertically and horizontally) relative to the chassis 1100. This enables the container support to move the container to store a container in and / or retrieve a container from a storage rack while the chassis remains stationary, increasing the overall stability of the vehicle 1300 during container movement and therefore reducing the likelihood of tipping or a container falling off of the vehicle 1300. The support assembly 1300 includes a support frame 1310; a container support 1320; a rail connector 1330; first, second, third, and fourth container-support mounts 1340a, 1340b, 1340c, and 1340d; and first, second, third, and fourth compression sensors 1350a, 1350b, 1350c, and 1350d.

[0061] The support frame 1310, which is best shown in Figure 14, is configured to support the container support 1320 and is movable relative to the chassis 1100 in a first direction (here, a vertical direction) under control of the first container-support actuator 1390a between a lower position (Figures 10A, 11 A, and 12A) and an upper position (Figures 10B, 11B, and 12B). The support frame 1310 includes spaced-apart first and second outer frame members 1312a and 1312b connected in any suitable manner (such as via fasteners or welding) by spaced-apart first, second, and third connecting frame members 1314a, 1314b, and 1314c. The first and second outer frame members 1312a and 1312b are substantially parallel to one another. The first, second, and third connecting frame members 1314a, 1314b, and 1314c are substantially parallel to one another and are transverse (and here, perpendicular) to the first and second outer frame members 1312a and 1312b such that the frame members form a substantially rectangular shape.

[0062] The support frame 1310 also includes first, second, third, and fourth container-support mounting rails 1316a, 1316b, 1316c, and 1316d that facilitate slidably mounting the container support 1320 to the support frame 1310. The first container-support mounting rail 1316a is connected to the first outer frame member 1312a near one of its ends and extends partially along the length of the first outer frame member 1312a. The second container-support mounting rail 1316b is connected to the first outer frame member 1312a near its opposite end and extends partially along the length of the first outer frame member 1312a. The first and second container-support mounting rails 1316a and 1316b are substantially aligned with one another. The third container-support mounting rail 1316c is connected to the second outer frame member 1312b near one of its ends and extends partially along the length of the second outer frame member 1312b. The fourth container-support mounting rail 1316d is connected to the second outer frame member 1312b near its opposite end and extends partially along the length of the second outer frame member 1312b. The third and fourth container-support mounting rails 1316c and 1316d are substantially aligned with one another and are substantially parallel to the first and second container-support mounting rails 1316a and 1316b.

[0063] This is merely one configuration of the support frame 1310, and it may be formed from any suitable components arranged in any suitable manner.

[0064] The container support 1320, which is best shown in Figures 15 and 16, is configured to support the container 200 and is movable relative to the chassis 1100 in the first direction (here, the vertical direction) under control of the first container-support actuator 1390a between a lower position (Figures 10A, 11A, and 12A) and an upper position (Figures 10B, 11B, and 12B) and relative to the chassis 1100 and the support frame 1310 in a second direction (here, the horizontal direction) under control of the second containersupport actuator 1390b between a home position (Figures 10A, 11A, and 12A) and an offset position (Figures 10B, 11B, and 12B). The container support 1320 includes spaced-apart first and second outer frame members 1322a and 1322b connected in any suitable manner (such as via fasteners or welding) by spaced-apart first, second, third, and fourth connecting frame members 1324a, 1324b, 1324c, and 1324d. The first and second outer frame members 1322a and 1322b are substantially parallel to one another. The first, second, third, and fourth connecting frame members 1324a, 1324b, 1324c, and 1324d are substantially parallel to one another and are transverse (and here, perpendicular) to the first and second outer frame members 1322a and 1322b such that the frame members form a substantially rectangular shape. The container support 1320 also includes planar first, second, third, and fourth mounting plates 1323a, 1323b, 1323c, and 1323d that facilitate mounting the container support 1320 to the container-support frame 1310, as described below. The first mounting plate 1323a is near the junction of the first outer rail 1322a and the first connecting rail 1324a and connected to one or more of those components. The second mounting plate 1323b is near the junction of the first outer rail 1322a and the third and fourth connecting rails 1324c and 1324d and connected to one or more of those components. The third mounting plate 1323c is near the junction of the second outer rail 1322b and the first connecting rail 1324a and connected to one or more of those components. The fourth mounting plate 1323d isnear the junction of the second outer rail 1322b and the third and fourth connecting rails 1324c and 1324d and connected to one or more of those components.

[0065] The container support 1320 also includes multiple container guides that are sized, shaped, positioned, oriented, and otherwise configured to guide a container into a desired container-support position on the container support 1320 and, once there, to support it. Specifically, the container support includes first and second front container guides 1326a and 1326b mounted to an outside wall of the first outer frame member 1322a; first and second rear container guides 1326c and 1326d mounted to an outside wall of the second outer frame member 1322b (and opposite the first and second front container guides); first and second left-side container guides 1328a and 1328b mounted to the ends of the first and second outer frame members 1322a and 1322b, respectively; and first and second right-side container guides 1328c and 1328d mounted to the other ends of the first and second outer frame members 1322a and 1322b, respectively (and opposite the first and second left-side container guides). Each container guide includes a substantially horizontal support wall and an angled guide wall extending from the support wall. For instance, the first left-side container guide includes a support wall 1328al and a guide wall 1328a2 extending from the support wall 1328al. The support and guide walls of the other container guides are not labeled for clarity.

[0066] As shown in Figure 16, the outer walls and ends of the first and second outer frame members 1322a and 1322b and the support walls of the container guides 1326a- 1326d and 1328a-1328d together define a lip-receiving area A that is sized, shaped, positioned, oriented, and otherwise configured to receive a bottom lip (not labeled) of the container 200 when the container 200 is received on and supported by the container support 1320 (and in this example embodiment, the support walls of the container guides 1326a- 1326d and 1328a-1328d). The components of the container support 1320 are sized such that the width W of the lip-receiving area A is slightly larger than the width of the bottom lip of the container 200 to account for manufacturing and assembly tolerances in the container 200 and the container support 1320. The guide walls of the container guides are sized, shaped, positioned, oriented, and otherwise configured to guide the container 200 to the desired container-support position in which its bottom lip is received in the lip-receiving area A should the container be offset from the lip-receiving area A as the container guide 1320 israised into contact with the bottom lip of the container. Specifically, because the guide walls are angled upward and away from the support walls, if the bottom lip of the container 200 is not aligned with the lip-receiving area A when the container support 1320 is raised, one or more of the guide walls engage the bottom lip of the container. Continued upward movement of the container support 1320 then results in the guide walls guiding the container such that its bottom lip is received in the lip-receiving area A.

[0067] This is merely one configuration of the container support 1320, and it may be formed from any suitable components arranged in any suitable manner.

[0068] The rail connector 1330 includes a support-assembly mount 1332 slidably mounted to the support-assembly mounting rail 1220 and a connecting member 1334 that connects the support-assembly mount 1332 to the support frame 1310. The rail connector 3120 is therefore slidably mounted to the support-assembly mounting rail 1220 such that the support assembly 1300 (and the support frame 1310 and the container support 1320 of the support assembly 1300) is movable relative to the chassis 1100 and the mast 1200 between a lower position (Figures 10A, 11A, and 12A) and an upper position (Figures 10B, 11B, and 12B).

[0069] As best shown in Figures 14 and 17, the container support 1320 is movably mounted to the support frame 1310 via the first, second, third, and fourth container-support mounts 1340a, 1340b, 1340c, and 1340d and the first, second, third, and fourth compression sensors 1350a, 1350b, 1350c, and 1350d such that the container support 1320 can move relative to the support frame 1310 between the home and offset positions. Specifically, the first, second, third, and fourth container-support mounts 1340a, 1340b, 1340c, and 1340d are slidably mounted to the first, second, third, and fourth containersupport mounting rails 1316a, 1316b, 1316c, and 1316d of the container support 1320, respectively. The first, second, third, and fourth compression sensors 1350a, 1350b, 1350c, and 1350d are attached to (such as via fasteners) the first, second, third, and fourth container-support mounts 1340a, 1340b, 1340c, and 1340d, respectively. The compression sensors are configured to sense compressive force. In this example embodiment the compression sensors are load cells, though they may be any other suitable sensors in other embodiments, such as strain gauges, compression force gauges, or torque gauges.

[0070] In this example embodiment, the container support 1320 is floatingly mounted to the support frame 1310 via the compression sensors 1350a, 1350b, 1350c, and 1350d such that the compression sensors 1350a, 1350b, 1350c, and 1350d carry the entire weight (or substantially the entire weight) of the container support 1320 and any container(s) thereon. Specifically, a first component connects the housing of each compression sensor (or the container-support mount itself) to a corresponding mounting plate of the container support. The first components are configured to enable movement of the container support relative to the compression sensors in the vertical direction but to prevent (or substantially prevent) movement of the container support relative to the compression sensors in the other directions. For instance, Figure 17 shows a first fastener 1391 connecting the third mounting plate 1323c of the container support 1320 to the housing of the third compression sensor 1350c. A second component extends between each mounting plate of the container support and the corresponding compression sensor. This enables the compression sensors to detect the compressive force applied by the weight of the container support (and any container(s) thereon). For instance, Figure 17 shows a second fastener 1392 connected to the third mounting plate 1323c of the container support 1320 and extending toward and engaging the third compression sensor 1350c.

[0071] The first container-support actuator 1390a is operably connected to the support assembly 1300 and configured to move the support assembly 1300 (and therefore the support frame 1310, the container support 1320, and the rail connector 1330) between the lower and upper positions. In this example embodiment, the first container-support actuator 1390a includes an electric motor operable to turn a lead screw to extend and retract a piston to move the support assembly 1300. This is merely one example, and the first container-support actuator may include any suitable actuator, such as a linear actuator, a hydraulic actuator, a pneumatic actuator, a scissor lift, a belt drive, or a rack-and-pinion actuator.

[0072] The second container-support actuator 1390b is operably connected to the container support 1320 and configured to move the container support 1320 between the home and offset positions. In this example embodiment, the second container-support actuator 1390b includes an electric motor operable to turn a lead screw to extend and retract a piston to move the container support 1320. This is merely one example, and the secondcontainer-support actuator may include any suitable actuator, such as a linear actuator, a hydraulic actuator, a pneumatic actuator, a scissor lift, a belt drive, or a rack-and-pinion actuator.

[0073] The first and second drive wheels 1410 and 1420 are mounted to the underside of the chassis 1100 adjacent opposite sides of the chassis 1100. The first and second drive wheels 1410 and 1420 have a common rotational axis and are positioned about halfway between the front and rear ends of the chassis 1100. The first drive-wheel actuator 1410a is mounted to the chassis 1100 and operably connected to the first drive wheel 1410 and configured to drive the first drive wheel 1410. The second drive-wheel actuator 1420a is mounted to the chassis 1100 and operably connected to the second drive wheel 1420 and configured to drive the second drive wheel 1420. The first and second drive-wheel actuators 1410a and 1420a include electric motors in this example embodiment, though they may include any other suitable actuator(s) in other embodiments. The first pair of undriven wheels 1430 and 1440 are mounted to the underside of the chassis 1100 adjacent opposite sides of the chassis 1100 and near the front end of the chassis 1100. The second pair of undriven wheels 1450 and 1460 are mounted to the underside of the chassis 1100 adjacent opposite sides of the chassis 1100 and near the rear end of the chassis 1100. The undriven wheels 1430, 1440, 1450, and 1460 are freely rotatable about both horizontal and vertical axes to provide the vehicle 300 with freedom of movement.

[0074] The first sensor 1370 is a suitable sensor configured to read the position identifiers 180 and 190 of the storage rack 100 and generate and send associated data to the vehicle controller. In certain embodiments, the first sensor is configured to decode the position identifier to determine the data representing the position and then to send that data to the vehicle controller. In other embodiments, the first sensor is configured to send other data to the vehicle controller such that the vehicle controller can determine the data representing the position. The particular type of sensor is selected based on the particular type of position identifier. In this example embodiment, the first sensor 1370 is in the form of a barcode reader pointing upward configured to read (and decode) the position identifiers 180 and 190 in the form of one-dimensional barcodes on the underside of the rails of the storage rack. The first sensor may be a QR code reader, an RFID tag reader, an NFC tag reader, or a Bluetooth-based device depending on the embodiment and the form of theposition identifiers. In this example embodiment, the first sensor 1370 is mounted to a shaft (not labeled) extending vertically from the chassis 1310 of the vehicle 300, though it may be mounted in any other suitable manner and location so long as it can read the position identifiers 180 and 190.

[0075] The second sensor 1380 is a suitable sensor configured to read the container identifier 280 of the container 200 and generate and send associated data to the vehicle controller. In certain embodiments, the second sensor is configured to decode the container identifier to determine the data representing the container and then to send that data to the vehicle controller. In other embodiments, the second sensor is configured to send other data to the vehicle controller such that the vehicle controller can determine the data representing the container. The particular type of sensor is selected based on the particular type of container identifier. In this example embodiment, the second sensor 1380 is in the form of a QR code reader pointing upward configured to read (and decode) the container identifier 280 in the form of a QR code on the underside of the bottom wall 219 of the container 200. The second sensor may be a barcode code reader, an RFID tag reader, an NFC tag reader, or a Bluetooth-based device depending on the embodiment and the form of the container identifier. In this example embodiment, the second sensor 380 is mounted to the container support 1320, though it may be mounted in any other suitable manner and location so long as it can read the container indicators 280.

[0076] The navigation devices of the vehicle include any suitable devices used to guide the vehicle 300. These devices can include (but are not limited to): magnetic sensors, laser sensors, gyroscopes, optical sensors, global positioning system receivers, radiofrequency identification sensors, near-field communication sensors, and / or proximity sensors.

[0077] The communications interface is configured to establish and facilitate bidirectional communication between the vehicle controller (described below) and an external device, such as the ASRS control system (described below). In operation, once the communications interface establishes communication with the external device, the vehicle controller can send data (via the communications interface) associated with the operation of the vehicle 300 to the external device and receive data (via the communications interface) from the external device. The communications interface may be any suitable wired orwireless communication interface having any suitable architecture and utilizing any suitable protocol such as, but not limited to 802.11 (Wi-Fi); 802.15 (including Bluetooth); 802.16 (WiMAX); 802.22; cellular standards such as CDMA, CDMA2000, and WCDMA; radio frequency (e.g., RFID); infrared; and near-field communication (NFC) protocols.

[0078] The vehicle controller includes a processing device (or devices) communicatively connected to a memory device (or devices). For instance, the vehicle controller may be a programmable logic controller. The processing device may include any suitable processing device such as, but not limited to, a general-purpose processor, a special-purpose processor, a digital-signal processor, one or more microprocessors, one or more microprocessors in association with a digital-signal processor core, one or more application-specific integrated circuits, one or more field-programmable gate array circuits, one or more integrated circuits, and / or a state machine. The memory device may include any suitable memory device such as, but not limited to, read-only memory, random-access memory, one or more digital registers, cache memory, one or more semiconductor memory devices, magnetic media such as integrated hard disks and / or removable memory, magneto-optical media, and / or optical media. The memory device stores instructions executable by the processing device to control operation of the vehicle controller. The vehicle controller is communicatively and operably connected to the first, second, third, and fourth compression sensors 1350a, 1350b, 1350c, and 1350d; the first and second sensors 1370 and 1380; the first and second container-support actuators 1390a and 1390b; the first and second drive-wheel actuators 1410a and 1420a; the navigation device; and the network interface to receive signals from and to control those components.

[0079] The vehicle controller is configured to determine the weight of any container(s) on the container support 1320 based on feedback received from the compression sensors 1350a-1350d in any suitable manner. In certain embodiments, before any containers are introduced atop the container support 1320, the vehicle controller determines the combined compressive force exerted on the compression sensors 1350a- 1350d based on feedback from the compression sensors. At this point, this combined compressive force represents the combined force the container support 1320 exerts on the compression sensors 1350a-1350d via its mass— in other words, the weight of the container support 1320. The compression sensors 1350a-1350d each detect a portion of that combinedcompressive force (which may or may not be the same for all four sensors) and send respective feedback (e.g., force readings) to the vehicle controller. The vehicle controller sums these readings to determine the combined compressive force. After one or more containers are introduced onto the container support 1320, the combined compressive force exerted on the compression sensors 1350a-1350d increases due to the weight of the container(s) (which includes the weight of the items stored in the containers). The vehicle controller sums these readings to determine the combined compressive force. The vehicle controller determines the weight of the container(s) by determining the difference between the combined compressive force without the container(s) and the compressive force with the container(s).

[0080] In other embodiments, the vehicle controller zeroes (or tares) the compression sensors after the container support is installed and before any containers are introduced onto the container support. In these embodiments, after zeroing the compression sensors no longer detect the weight of the container support, so the weight of any later-introduced containers is equal to the force reading received from the compression sensors.

[0081] The vehicle controller and / or the ASRS control system may use the determined weight of the container(s) in any suitable manner. In one example embodiment, the ASRS control system is configured to compare the determined weight of a container with an actual weight of the container that is stored in a database. This enables the ASRS control system to confirm that the vehicle picked the correct container — if the determined weight matches or substantially matchers the actual weight, the vehicle picked the correct container (and vice-versa).

[0082] The power source 1500 may include a battery or any other suitable component, such as a supercapacitor, configured to power the actuators and other electrically powered components of the vehicle 300. In this example embodiment, the power source 1500 is supported by the chassis between the first and second drive wheels 1410 and 1420 and the first pair of undriven wheels 1430 and 1440. In other embodiments, the power source is not part of the vehicle 300.

[0083] The illustrated vehicle 300 is merely one example vehicle, and any suitable vehicle having any suitable configuration may be used in conjunction with the storage rack 100 and the containers 200.

[0084] The ASRS control system C includes a processing device (or devices) communicatively connected to a memory device (or devices). For instance, the controller may be a programmable logic controller. The processing device of the ASRS control system C may include any suitable processing device such as, but not limited to, a general-purpose processor, a special-purpose processor, a digital-signal processor, one or more microprocessors, one or more microprocessors in association with a digital-signal processor core, one or more application-specific integrated circuits, one or more field-programmable gate array circuits, one or more integrated circuits, and / or a state machine. The memory device of the ASRS control system C may include any suitable memory device or computer- readable medium such as, but not limited to, read-only memory, random-access memory, one or more digital registers, cache memory, one or more semiconductor memory devices, magnetic media such as integrated hard disks and / or removable memory, magneto-optical media, and / or optical media.

[0085] The memory device of the ASRS control system C stores instructions executable by the processing device to control operation of the ASRS 10 to carry out various loading and unloading processes. The ASRS control system C is communicatively and operably connected to the vehicles 300 to receive signals from and to control those vehicles 300. For instance, the ASRS control system C may include a database for keeping track of the containers 200, including their contents and their locations (both the particular storage area and the particular location in the stack of containers at that storage area); a routing planner for finding optimal routes for the vehicles 300; and a communications interface for communicating instructions to the vehicles 300 (and particularly, to the vehicle controllers). The ASRS control system C typically communicates with a central computer where orders and tasks are transmitted to the ASRS control system C.

[0086] Operation of the ASRS 10 to carry out a loading process to load a container 200 into the sixth storage area SA6 of the storage rack 100 using the vehicle 300 is now described. The loading process begins by positioning the container 200 (such as via an operator or an automated system) on the container support 1320 of the vehicle 300. Once thecontainer 200 is on the container support 1320, the ASRS control system C confirms that the container 200 is the container desired to be loaded in to the sixth storage area SA6. To do so, the second sensor 1380 of the vehicle 300 reads the container identifier 280 and sends appropriate data to the ASRS control system C via the vehicle controller. Using that data, the ASRS control system C determines the data representing the container and determines whether the container 200 is the container desired to be loaded into the storage rack 100. If not, an error is generated and the process ends.

[0087] But if the ASRS control system C confirms that the container 200 is the correct container, with the container support 1320 in its lower and home positions, the vehicle 300 begins moving in the X-direction. As it does so, the ASRS control system C monitors the position of the vehicle 300. To do so, the first sensor 1370 of the vehicle 300 reads the position identifiers 180 on the underside of the rail 120a and sends appropriate data to the ASRS control system C (via the vehicle controller). Using that data, the ASRS control system C determines the data representing the position. Once the vehicle 300 reaches the third row R3, the ASRS Control system C controls the vehicle 300 to stop moving in the X-direction and to turn and start moving down the third row R3 in the Y- direction. As it does so, the ASRS control system C monitors the position of the vehicle 300. To do so, the first sensor 1370 of the vehicle 300 reads the position identifiers 190 on the underside of the rails 130d and 130h and sends appropriate data to the ASRS control system C (via the vehicle controller). Using that data, the ASRS control system C determines the data representing the position. Once the ASRS control system C determines that the vehicle 300 is beneath the sixth storage area SA6, it controls the vehicle 300 to stop and load the container 200.

[0088] In various embodiments, the ASRS control system is configured to use feedback from the first sensor of the vehicle to determine whether the vehicle is moving solely in the X- or Y-direction (i.e., parallel to the rails) or is moving in both the X- and Y- directions. For instance, if ASRS control system controls the vehicle to move in the Y- direction and the first sensor stops reading the position identifiers after a period of time, the ASRS control system determines that the vehicle has veered off course and controls the vehicle to correct itself until the first sensor again begins to read the position identifiers. In another example, the ASRS control system monitors the rate at which the first sensor readsposition identifiers. Assuming the position identifiers are evenly spaced and the vehicle is moving at a constant velocity, the rate should be substantially the same from the point the vehicle begins moving to the point it stops moving. If the rate increases — which means the time between readings increases — the control system determines that the vehicle has veered off course and controls the vehicle to correct itself.

[0089] Operation of the ASRS 10 to load a container 200 into the storage rack 100 using a vehicle 300 is now described with respect to Figures 19A-19E.

[0090] The process begins by moving the container to a position beneath a storage area of the storage rack. Here, the container 200 is positioned (such as via an operator or an automated system) on the container support 1320 of the vehicle 300, as shown in Figure 19A. With the container support 1320 in its lower and home positions, the vehicle 300 moves in the X- and / or Y-directions beneath the storage area SA2 so the rack engagers 220, 230, 240, and 250 of the container 200 are horizontally aligned with the container supports 140c-140f, respectively, as shown in Figure 19A. In this context, when a rack engager is "horizontally aligned" with a container support, the rack engager is above or beneath the rack-engager receiver of that container support so the engagement surface of the rack engager can engage the rack-engager receiver when the container is raised or lowered.

[0091] The process continues by moving the container until the rack engagers of the container are horizontally offset from the container supports. In this context, when a rack engager is "horizontally offset" from a container support, the rack engager is not directly above or beneath the rack-engager receiver of that container support so the rack engager does not engage the rack-engager receiver when the container is raised or lowered. Here, the second container-support actuator 1390b moves the container support 1320 to the offset position at which point the rack engagers 220, 230, 240, and 250 of the container 200 are horizontally offset from the container supports 140c-140f, respectively, as shown in Figure 19B.

[0092] The process continues by moving the container until the rack engagers of the container are above the rack-engager receivers of the container supports of the storage rack. Here, the first container-support actuator 1390a raises the container support 1320 until the rack engagers 220, 230, 240, and 250 of the container 200 are above the containersupports rack-engager receivers container supports 140c-140f, respectively, as shown in Figure 19C. Because the rack engagers were horizontally offset from the rack-engager receivers, the rack engagers did not contact the rack-engager receivers as the container was raised.

[0093] The process continues by moving the container until the rack engagers of the container are above and horizontally aligned with the container supports. Here, second container-support actuator 1390b moves the container support 1320 to the home position at which point the rack engagers 220, 230, 240, and 250 of the container 200 are above and horizontally aligned with the container supports 140c-140f, respectively, as shown in Figure 19D.

[0094] The process concludes by moving the container until the rack engagers of the container engage the rack-engager receivers of the container supports of the storage rack and support the container above a support surface. Here, the first container-support actuator 1390a lowers the container support 1320 to the lower position. The container 200 initially travels with the container support 1320. Eventually, this descent of the container 200 relative to the container supports 140c-140f results in the engagement surfaces of the rack engagers 220, 230, 240, and 250 engaging the walls of the rack-engager receivers 140c- 140f, respectively. Continued descent of the container support 1320 results in the container supports supporting the container 200 above the floor and the container support 1320 disengaging the container 200 as it returns to its lower position, as shown in Figure 19E.

[0095] The rack-engager receivers 143 and 145 of the container supports 140 and the rack engagers 220, 230, 240, and 250 of the container 200 are sized, shaped, positioned, oriented, and otherwise configured to guide the container 200 to a storage position as the vehicle 300 lowers the container onto the rack-engager receivers. In this example embodiment, the container 200 is in the storage position when the fifth walls (i.e., the horizontal walls) of the rack engagers engage and are supported by the support walls (i.e., the horizontal walls) of the corresponding container supports. In certain scenarios, such as the one shown in Figures 19A and 19E and described above, when the container is lowered into engagement with the rack-engager receivers of the container supports, the container is positioned such that the fifth walls of the rack engagers are horizontally aligned with thesupport walls of the rack-engager receivers and the fifth walls do not engage any of the guide walls of the rack-engager receivers as the container is lowered.

[0096] In other scenarios, such as due to irregular flooring, manufacturing or assembly tolerances, or imprecise movement of the vehicle or the container support, this perfect alignment does not exist and the fifth walls of the rack engagers are slightly offset from the support walls of the rack-engager receivers. Figure 20A shows one such scenario. When this occurs, the orientation of the guide walls of the rack-engager receivers and the shape of the walls of the rack engager result in movement of the container into the storage position as the vehicle lowers the container. In this example, as the container 200 is lowered relative to the container supports 140, the fourth wall 224 of the first rack engager 220 and the third wall 233 of the second rack engager 230 engage the second guide walls 143c of the corresponding rack-engager receivers 143, as shown in Figure 20B. Continued lowering of the container 200 results in the second guide walls 143c guiding the container 200 to the storage position, as shown in Figure 20C.

[0097] In certain embodiments, instead of or in addition to using position identifiers and associated sensors to locate the vehicle, the vehicle includes a suitable imaging device, such as a 3D camera, and the ASRS control system includes suitable image processing software configured to use feedback from the imaging device to locate the vehicle.

Claims

Claims1. An automated storage and retrieval system comprising: a storage rack comprising multiple container supports and multiple rails, wherein the rails define multiple storage areas, wherein one or more of the rails support one or more position identifiers each associated with a unique position; a vehicle including a chassis, one or more driven wheels, a lift device vertically movable relative to the chassis from a lower position, and a first sensor configured to read the one or more position identifiers; a container including multiple walls and multiple rack engagers configured to engage the container supports of the storage rack; and a controller communicatively connectable to the vehicle and configured to: with the lift device of the vehicle supporting the container, control the vehicle to move the container toward a loading position beneath a designated storage area of the storage rack; as the vehicle moves toward the loading position, determine the position of the vehicle based on data received from the first sensor responsive to the first sensor reading one or more of the position identifiers; and when the vehicle reaches the loading position: control the vehicle to move the container until the rack engagers of the container are above the container supports; and control the vehicle to move the container until the rack engagers of the container engage the respective container supports and the container supports support the container above a support surface.

2. The system of claim 1, wherein the container comprises a container identifier, wherein the vehicle further comprises a second sensor configured to read the container identifier.

3. The system of claim 2, wherein the controller is further configured to, with the lift device of the vehicle supporting the container, identify the container based on datareceived from the second sensor responsive to the second sensor reading the container identifier.

4. The system of claim 3, wherein the container identifier comprises optically readable indicia.

5. The system of claim 1, wherein the position identifiers comprise optically readable indicia.

6. The system of claim 5, wherein the position identifiers are on an underside of one or more of the rails.

7. The system of claim 6, wherein the first sensor is directed upward.

8. A method of storing a container in a storage rack, the method comprising: receiving, on a lift device of a vehicle, the container; moving the vehicle toward a loading position beneath a designated storage area of the storage rack; as the vehicle is moving toward the loading position, reading, via a first sensor of the vehicle, one or more position identifiers of the storage rack; determining the position of the vehicle based on the read position identifiers; and responsive to the vehicle reaching the loading position: moving the container until rack engagers of the container are above respective container supports of the storage rack; and moving the container until the rack engagers of the container engage the respective container supports and the respective container supports support the container above a support surface.

9. The method of claim 8, further comprising reading, via a second sensor of the vehicle, a container identifier of the container after the lift device receives the container.

10. The method of claim 9, further comprising identifying the container based on the read container identifier.

11. A vehicle for an automated storage and retrieval system, the vehicle comprising: a chassis; a container support movable relative to the chassis in a first direction between a lower position and an upper position and in a second direction between a home position and an offset position, wherein the second direction is transverse to the first direction; one or more container-support actuators operably connected to the container support and configured to move the container support from the lower position to the upper position and from the home position to the offset position; one or more drive wheels supported by the chassis; and one or more drive-wheel actuators operably connected to the one or more drive wheels and configured to drive the one or more drive wheels.

12. The vehicle of claim 11, wherein the one or more container-support actuators are configured to move the container support between the lower position and the upper position and between the home position and the offset position.

13. The vehicle of claim 11, further comprising a support frame to which the container support is mounted, wherein the support frame is movable relative to the chassis in the first direction from a support-frame lower position to a support-frame upper position to move the container support from the lower position to the upper position.

14. The vehicle of claim 13, wherein the container support is movable relative to the support frame between the home and offset positions.

15. The vehicle of claim 14, wherein the one or more container-support actuators comprise: a first container-support actuator operably connected to the support frame and configured to move the support frame from the support-frame lower position to the support-frame upper position; and a second container-support actuator operably connected to the container support and configured to move the container support from the home position to the offset position.

16. The vehicle of claim 15, wherein the first container-support actuator is configured to move the support frame between the support-frame lower position and the support-frame upper position.

17. The vehicle of claim 16, wherein the second container-support actuator is configured to move the container support between the home and offset positions.

18. The vehicle of claim 13, wherein the support frame comprises multiple container-support mounting rails and multiple container-support mounts, wherein each container-support mount is slidably mounted to one of the container-support mounting rails, and wherein the container support is connected to the container-support mounts.

19. The vehicle of claim 18, wherein the container support further comprises one or more compression sensors configured to sense compressive force imparted by a container supported by the container support.

20. The vehicle of claim 19, wherein each of the one or more compression sensors is mounted to a different one of the container-support mounts, wherein the container support is connected to the container-support mounts such that the one or more compression sensors can sense compressive force imparted by the container supported by the container support.

21. The vehicle of claim 13, wherein the first direction is a vertical direction and the second direction is a horizontal direction.

22. The vehicle of claim 11, wherein the container support comprises multiple frame members and multiple container guides each connected to one of the frame members, wherein the frame members and the container guides together define a lip-receiving area sized and shaped to receive a bottom lip of a container.

23. The vehicle of claim 22, wherein each container guide includes a support wall and a guide wall extending away from and upward from the support wall.

24. The vehicle of claim 23, wherein the container guides are positioned and oriented such that the guide walls of the container guides are configured to guide the bottom lip of the container into the lip-receiving area.

25. An automated storage and retrieval system comprising: a storage rack including multiple container supports and defining a storage area, wherein a first one of the container supports comprises a rack-engager receiver having a substantially concave shape; a vehicle including a chassis, one or more driven wheels, and a lift device vertically movable relative to the chassis between a lower position and an upper position; and a container including multiple walls and multiple rack engagers configured to engage the rack-engager receivers of the container supports of the storage rack.

26. The automated storage and retrieval system of claim 25, wherein the rack engager of the first container support comprises a support wall and first and second guide walls extending from the support wall, wherein the support wall and the first and second guide walls form the substantially concave shape of the rack engager.

27. The automated storage and retrieval system of claim 25, wherein the container support comprises a body to which the rack engager is connected.

28. The automated storage and retrieval system of claim 27, wherein the body comprises opposing first and second legs and a connector connecting the first and second legs, wherein the connector and the first and second legs form a U-shape.

29. The automated storage and retrieval system of claim 28, wherein the rack engager of the first container support comprises a support wall and first and second guide walls extending from the support wall, wherein the support wall and the first and second guide walls form the substantially concave shape of the rack engager.

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