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

Abstract

There are provided systems and methods that may involve transit areas at automated storage and retrieval systems. In one form, the system may include a storage structure including storage locations and pathways to be traversed by mobile robots to access the storage locations. The system may also include a transit area adjoining the storage structure and providing access to mobile robots. The transit area may include a frame portion formed of beams for coupling to the storage structure and a floor supported by the frame portion. The floor may include panels with at least one panel that may include guidelines at predetermined locations to facilitate movement of the mobile robots thereon. There is also provided a panel and a method of construction.

Description

AUTOMATED STORAGE AND RET IEVAL SYSTEM WITH MODULARTRANSIT AREA AND METHOD OF CONSTRUCTIONCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims the benefit of and priority to U.S. Provisional Application Number 63 / 472,885, filed June 14, 2023, which is incorporated by reference herein in its entirety.TECHNICAL FI ELD

[0002] This invention relates generally to an automated storage and retrieval system for storing goods, and more particularly, to a modular transit area for the navigation and movement of mobile robots.BACKGROUN D

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

[0004] There is a need for an area where the mobile robots may navigate and may access different aisles. An in rack transit plane ( IRTP), or transit area or support deck, may be desirable to allow the mobile robots to access different aisles and different areas of the storage structure and facility. It would be desirable to provide for the manufacture and assembly of a support deck with modular and configurable prefabricated panels that may support and help guide the robots. BRI EF DESCRI PTION OF DRAWINGS

[0005] Disclosed herein are embodiments of systems, apparatuses and methods involving transit areas and panels, such as may be used at automated storage and retrieval systems. This description includes drawings, wherein:

[0006] FIG. 1 is a perspective view of an automated storage and retrieval system in accordance with some embodiments;

[0007] FIG. 2 is a partial perspective view of the automated storage and retrieval system of FIG.1 in accordance with some embodiments;

[0008] FIG. 3 is a partial perspective view of the automated storage and retrieval system of FIG. 1 in accordance with some embodiments;

[0009] FIG. 4 is a partial perspective view of the automated storage and retrieval system of FIG. 1 in accordance with some embodiments;

[0010] FIG. 5 is a perspective view of a transit area in accordance with some embodiments;

[0011] FIG. 6 is a perspective view of the transit area of FIG. 5 in accordance with some embodiments;

[0012] FIG. 7 is a perspective view of the transit area of FIG. 5 in accordance with some embodiments;

[0013] FIG. 8 is a partial perspective view of the transit area of FIG. 5 in accordance with some embodiments;

[0014] FIG. 9 is a top view of a panel in accordance with some embodiments;

[0015] FIG. 10 is a schematic view of the panel of FIG. 9 in accordance with some embodiments;

[0016] FIG. 11 is a partial top view a panel at a transit area in accordance with some embodiments;

[0017] FIG. 12 is a partial perspective view of the panel at the transit area of FIG. 11 in accordance with some embodiments;

[0018] FIG. 13 is a partial perspective view the panel at the transit area of FIG. 11 in accordance with some embodiments; and

[0019] FIG. 14 is a flow diagram in accordance with some embodiments.

[0020] Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and / or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well- understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and / or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.DETAI LED DESCRIPTION

[0021] The following description is not to be taken in a limiting sense but is made merely for the purpose of describing the general principles of exemplary embodiments. Reference throughout this specification to "one form," "one embodiment," "an embodiment," "some embodiments", "an implementation", "some implementations", "some applications", or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases "in one embodiment," "in an embodiment," "in some embodiments", "in some implementations", and similar language throughout this specification do not all refer to the same embodiment.

[0022] The terms "top" and "bottom," "upper" and "lower" and "vertical" and "horizontal as may be used herein are by way of example and illustrative purposes only and are not meant to limit the description of the embodiments inasmuch as the referenced item can be exchanged in position and orientation. Also, as used herein, the terms "substantially" and / or "about" mean that the specified dimension or parameter may be varied within an acceptable manufacturing tolerance for a given application.

[0023] Generally speaking, pursuant to various embodiments, systems, apparatuses and methods are provided herein for an automated storage and retrieval system. In one form, the system includes: a first storage structure comprising a plurality of storage locations configured to store totes containing goods, the first storage structure including a first plurality of pathways, each storage location accessible by a pathway, the pathways configured to be traversed by a plurality of mobile robots, each mobile robot configured to access a storage location to deposit or retrieve a tote at the storage location; and a transit area adjoining the first storage structure providing access to mobile robots to enter or exit at least some of the pathways, the transit area including: a frame portion formed of a plurality of beams configured for coupling to the first storage structure; and a floor supported by the frame portion, the floor comprising a plurality of panels collectively defining the floor, at least one panel including one or more guidelines at predetermined locations of the at least one panel to facilitate movement of the mobile robots thereon.

[0024] In some implementations, in the system, the one or more guidelines include one or more magnetic guidelines and the at least one panel further includes at least one groove configured to receive compression fit metal material therein to form the one or more magnetic guidelines. Insome implementations, at least one mobile robot includes a magnetic sensor to detect the one or more magnetic guidelines to facilitate movement of the at least one mobile robot on the at least one panel. In some implementations, the at least one panel further includes an alignment feature configured to align the one or more guidelines in a predetermined manner with respect to a corresponding pathway configured for entry and exit of mobile robots between the corresponding pathway and the at least one panel. In some implementations, the alignment feature includes at least two mounting holes at predetermined positions of the at least one panel, the at least two mounting holes each configured to receive a fastener therein. In some implementations, the at least one panel includes at least one fiducial marker applied to a top surface of the at least one panel, the at least one fiducial marker configured to facilitate determination of position and navigation by mobile robots. In some implementations, the at least one panel includes at least one radio frequency identification (RFID) tag applied to a bottom surface of the at least one panel, the at least one RFID tag configured to facilitate determination of position and navigation by mobile robots. In some implementations, the system further includes a transition plate disposed between one panel of the at least one panels and a corresponding pathway, the transition plate configured for coupling to the alignment feature of the one panel for alignment of the transition plate with the one panel and with the corresponding pathway. In some implementations, the system further includes a first plurality of mounting brackets, each mounting bracket coupling a first end of each beam to a corresponding end of the first storage structure. In some implementations, the system further includes: a second storage structure comprising a plurality of storage locations configured to store totes containing goods, the second storage structure comprising a second plurality of pathways, each storage location accessible by a pathway; and a second plurality of mounting brackets, each mounting bracket coupling a second end of each beam to a corresponding end of the second storage structure.

[0025] In another form, there is provided a transit area for an automated storage and retrieval system including: a frame portion formed of a plurality of beams configured to couple to a first storage structure, the first storage structure including a plurality of storage locations configured to store totes containing goods, the first storage structure including a first plurality of pathways, each storage location accessible by a pathway, the pathways configured to be traversed by a plurality of mobile robots, each mobile robot configured to access a storage location to deposit or retrieve a tote at the storage location; and a floor supported by the frame portion, the floorcomprising a plurality of panels, at least one panel comprising one or more guidelines to facilitate movement of the mobile robots thereon.

[0026] In another form, there is provided a panel for supporting mobile robots traveling on the panel, the panel including: one or more magnetic guidelines formed in a top surface of the panel at predetermined locations to facilitate movement of the mobile robots along the top surface; at least one groove formed in the top surface of the panel, the at least one groove configured to receive metal material therein to form the one or more magnetic guidelines; and an alignment feature configured to align the one or more magnetic guidelines in a predetermined manner with respect to a corresponding pathway configured for entry and exit of mobile robots between the corresponding pathway and the panel. The panel may also include some or all of the other features addressed above.

[0027] In yet another form, there is provided a method of constructing an automated storage and retrieval system, the method including: providing a storage structure including a plurality of storage locations configured to store totes containing goods, the storage structure including a plurality of pathways, each storage location accessible by a pathway the pathways configured to be traversed by a plurality of mobile robots, each mobile robot configured to access a storage location to deposit or retrieve a tote at the storage location; coupling a frame portion of a transit area to the storage structure by coupling a plurality of beams to the storage structure, the transit area allowing mobile robots to enter or exit the pathways; and installing a floor supported by the frame portion, the floor formed by a plurality of panels collectively defining the floor, at least one panel including one or more guidelines at predetermined locations of the at least one panel to facilitate movement of the mobile robots thereon.

[0028] In some implementations, the method may further include receiving the at least one panel as pre-formed with at least one groove receiving compression fit metal material therein to form the one or more guidelines prior to installation of the floor. In some implementations, the method may further include applying at least one fiducial marker to the at least one panel following installation of the floor, the at least one fiducial marker configured to facilitate determination of position and navigation by mobile robots traveling on the floor. In some implementations, the method may further include applying at least one RFID tag to the at least one panel following installation of the floor, the at least one RFID tag configured to facilitate determination of position and navigation by mobile robots traveling on the floor. In some implementations, the method may further include receiving the at least one panel with analignment feature aligning the one or more guidelines in a predetermined manner with respect to a corresponding pathway configured for entry and exit of mobile robots between the corresponding pathway and the at least one panel. In some implementations, the alignment feature includes at least two mounting holes at predetermined positions of the at least one panel, the at least two mounting holes each configured to receive a fastener therein.

[0029] In one aspect, and without limitation, this disclosure is directed generally to reducing excessive labor and time in installation of a transit area connected to a storage structure. This transit area may be generally configured for use by mobile robots that are retrieving totes of goods that are stored in specific storage locations in the adjacent storage structure, which is part of an automated storage and retrieval system. This transit area may allow robots to access different regions of an automated storage and retrieval system form the storage structure. The robots may use various features for navigation and positional awareness, which may need to be created at substantial cost and risk within custom constructions. Typically, construction of the transit area may be done on-site and may involve layers of installation procedures that pose multiple opportunities for error. The installation procedure may include building a frame and setting a floor, followed by construction of navigational features and posts for maneuvering robots.

[0030] In one aspect, and without limitation, this disclosure makes use of the manufacture of modular components in a factory setting with prefabricated panels (or tiles) that can be assembled with high efficiency and low risk. Further, this disclosure provides for the manufacture of guidelines in panel surfaces for robot transit. Additional features may also be incorporated into panel surfaces for positional awareness of the robots. This innovation allows for a modular and scalable construction of the transit area, thereby reducing cost and eliminating assembly risk. It also reduces the amount of onsite fabrication work.

[0031] FIGS. 1 and 2 show views of an automated storage and retrieval system 100. In one form, this system 100 may be incorporated, wholly or partially, into an order fulfillment facility. The system 100 may include one or more storage structures 102 having a number of storage locations 104. Each storage structure 102 may include a y-z array of storage locations in horizontal rows and level changing vertical towers. Mobile robots 108 may travel between storage levels in the z- direction within the level changing towers. The storage structures 102 may form pairs of storage bays 110 that are arranged to face each other, separated by pathways 112. In one form, the pathways 112 may be in the form of aisles, and an aisle 112 may have a width such that a mobilerobot 108 traveling within an aisle 112 may transfer containers to (or retrieve containers from) the storage bays 110 on either side of the aisle 112. It is generally contemplated that the mobile robots 108 may transport totes of goods from the storage locations 104 to some designated area for pick-up of the goods. In some forms, the mobile robots 108 may also carry totes containing goods to be returned to the storage structure 102.

[0032] FIGS. 1 and 2 show examples of transit areas 114, or in rack transit planes (IRTPs), which are discussed in more detail below. The transit areas 114 may be positioned at different vertical levels between the storage structures 102. The transit area 114 may enable a mobile robot 108 to access different aisles of a storage structure 102, to access different storage structures, or to access other areas of the system or facility.

[0033] As noted above, the automated storage and retrieval system 100 may utilize a number of mobile robots 108 for transferring totes or other product or order containers to and from the storage locations 104. The term "tote" refers broadly to any sort of container that can be used to hold goods. The mobile robots 108 may be self-guided and / or rail-guided so as to move horizontally and vertically within aisles 112 to transfer totes or other product containers between the mobile robots 108 and storage locations 104. The mobile robots 108 may have access to storage shelves on either side of an aisle 112 in the x-direction on a given level. As stated, the system 100 may also include vertical level changing towers within which the mobile robots 108 may travel vertically in the z-direction between levels of storage locations 104.

[0034] Further details of various embodiments of storage structures, mobile robots, and other aspects of automated storage and retrieval systems that may be used are described, for example, in the following U.S. patents and patent applications: U.S. Patent No. 9,139,363; U.S. Patent No. 10,435,241; U.S. Patent No. 11,142,398; U.S. Patent No. 10,984,375; U.S. Patent No. 10,952,533; U.S. Patent No. 11,267,651; U.S. Patent Application No. 63 / 127,762; and U.S. Patent Application No. 17 / 957,266. Each of these patents and applications are incorporated by reference herein in their entirety.

[0035] FIG. 3 shows a portion of the automated storage and retrieval system 100 with some of the storage structure removed for clarity. FIG. 3 shows three transit areas 114 at different vertical levels, i.e., stacked, that are intermediate of and connect two storage structures 102A and 102B. As explained further below, each transit area 114 is generally in the form of a floor of panels supported by a frame of beams. The end of each transit area 114 is attached to an upright 116 at a corresponding end of each storage structure 102A and 102B. In one form, it is contemplatedthat mobile robots 108 retrieve totes containing goods from storage locations 104 within each storage structure 102A and 102B. The transit area 114 allows mobile robots 108 exiting an aisle 112 from storage structure 102A to turn and enter a different aisle 112 in the same storage structure 102A, to orient itself and enter a selected aisle 112 in the second storage structure 102B, or to travel to a different area (such as a designated order pickup area) within the automated storage and retrieval system 100.

[0036] FIG. 4 shows another portion of the automated storage and retrieval system 100 with some of the storage structure removed for clarity. FIG. 4 shows two transit areas 114 at different vertical levels that are adjacent to a storage structure 102. One end of each transit area 114 is attached to an upright 116 at a corresponding end of the storage structure 102. The other end of each transit area 114 is attached to another upright 116. The transit area 114 allows mobile robots 108 exiting an aisle 112 from storage structure 102 to turn and enter a different aisle 112 in the same storage structure 102 or to travel to a different area (such as a designated order pickup area) within the automated storage and retrieval system 100.

[0037] Accordingly, in some forms, the automated storage and retrieval system 100 includes one or more storage structures 102 and multiple mobile robots 108. In one form, the system 100 may include a first storage structure 102A that includes a plurality of storage locations 104 configured to store totes containing goods. The first storage structure 102A may include a plurality of aisles 112 with each storage location 104 accessible by an aisle 112. The system 100 may also include a plurality of mobile robots 108 configured to traverse the plurality of aisles 112 of the first storage structure 102A. Each mobile robot 108 may be configured to access a storage location 104 to deposit or retrieve a tote at the storage location 104. The system 100 may also include a second storage structure 102B including a plurality of storage locations 104 configured to store totes containing goods with the second storage structure 102B including a plurality of aisles 112 and with each storage location 104 accessible by an aisle 112.

[0038] Referring to FIG. 5, there is a shown a partially assembled transit area 114. In the figure, only the supporting ends of the storage structure(s) 102 are shown. The transit area 114 includes a frame portion 118 and a floor 120. The frame portion 118 includes several beams 122 that attach to one or more storage structures 102. In the example of FIG. 3, the two ends of the beams attach to corresponding ends of the storage structures 102A and 102B. In the example of FIG. 4, one end of the beams attaches to a corresponding end of storage structure 102, while the otherend of the beams attaches to the upright 116. In turn, the beams 122 of the frame portion 118 support the floor 120.

[0039] FIGS. 6 and 7 show an assembled transit area 114. In one form, the transit area 114 may be composed of two types of panels: transit panels 124 and connecting panels 126. In the figure, in this particular example, there are four transit panels 124. Each transit panel 124 may include guidelines 128 that extend along two centerlines of each transit panel 124, which subdivide each transit panel 124 into four sections. These guidelines 128 allow guided movement by the mobile robots 108 along these centerlines, as explained further below. The connecting panels 126 extend in a central strip between two sets of transit panels 124. In this form, the panels 124 and 126 are fastened to each other by cleats 130, as also shown in FIG. 8. These cleats 130 are optional, and in another form, it is contemplated that alternative fasteners may be used. Also, as can be seen in FIG. 7, a transition plate 132 may be provided that connects and aligns an aisle 112 in a storage structure 102 with a guideline 128 of the panel 124. This transition plate 132 is described in more detail below.

[0040] Thus, in some forms, the system 100 may include a transit area 114 adjoining the first storage structure 102A providing access to mobile robots 108 to enter or exit aisles 112 of a storage structure 102. The transit area 114 may include a frame portion 118 formed of a plurality of beams 122 configured for attachment to a first storage structure 102A. In addition, the system 100 may include a floor 120 supported by a frame portion 118 with the floor 120 formed by a plurality of panels collectively defining the floor 120. The floor 120 may include at least one panel 124 having one or more guidelines 128 at predetermined locations of the panel(s) 124 to facilitate movement of the mobile robots 108 thereon.

[0041] Referring to FIG. 9, there is shown a top view of a panel 200. In one form, it is contemplated that panels 200 with the following described features may be used generally in transit areas 114 and in automated storage and retrieval systems 100. They may be prefabricated, in whole or in part, and used in a modular manner in the floors of transit areas 114. In another form, it is contemplated that the panels 200 may be used in other circumstances where it is desirable to provide a surface for movement and navigation of mobile robots thereon.

[0042] The panel 200 may be generally rectangular in shape and may include two guidelines 202 formed generally along horizontal and vertical centerlines of the panel 200. In this form, a robot may proceed along one of the centerlines and then either proceed straight or turn at, or as it approaches, the intersection of the two centerlines. Although the guidelines 202 are shown asformed along the horizontal and vertical centerlines of the panel 200, it is contemplated that other forms of guidelines may also be used. For example, the guidelines 202 may be arranged at some predetermined non-perpendicular angle with respect to the edges of the panel. Further, it is contemplated that the guidelines may be in the form of spaced patterns at predetermined positions on the panel 200 that the robots can detect and use for navigation. Other robotic guides are also available.

[0043] In one form, the guidelines 202 may be magnetic and at least one groove is configured to receive compression fit metal material therein to form the one or more magnetic guidelines 202. In this form, the magnetic guidelines 202 may be created by pressing the magnetic material into a groove designed to capture the line with a compression fit without the need for adhesive. It is also contemplated that these magnetic guidelines 202 may be prefabricated by a panel manufacturer at a separate location, prior to shipment and installation to form the floor 120 of a transit area 114. In one form, the panels may be formed, in part, of a resin material.

[0044] Referring to FIG. 10, there is shown a schematic side view of a panel 200 with a mobile robot 108 traveling above the panel 200. As can be seen, the panel 200 includes a magnetic guideline 202 formed in the top surface of the panel 200. In one form, it is contemplated that the mobile robot 108 may include a magnetic sensor 109 to detect the one or more magnetic guidelines 202 to facilitate movement of the mobile robot 108 on the panel 200. This magnetic sensor 109 may be a Hall effect sensor and may be disposed at the bottom of the mobile robot 108. In some circumstances, it may be desirable to use magnetic guidelines 202, rather than painted guidelines. Painted guidelines may tend to wear away over time and may not be sensed by optical sensors of mobile robots 108 under certain conditions, such as, for example, when mobile robots 108 move in and out of temperature-controlled environments. Under these conditions, the optical sensor used to follow a painted line may become fogged and inoperable.

[0045] FIG. 9 also shows an alignment feature for aligning the panel 200 in a certain orientation, such as for installation in a transit area 114. In one form, the panel 200, may include an alignment feature for aligning the magnetic guidelines 202 in a predetermined manner with respect to a corresponding aisle 112 configured for exit of mobile robots 108 from the corresponding aisle 112 to the panel 200. This alignment feature may include at least two mounting holes 208 at predetermined positions of the panel 200 with these mounting holes 208 each configured to receive a fastener therein. As can be seen, in one form, these mounting holes 208 may bedisposed near an edge of the panel 200 corresponding to the longer leg of a rectangle. These mounting holes 208 receive a fastener that affixes the panel 200 to underlying beams 122.

[0046] In one aspect, these mounting holes 208 align a magnetic guideline 202 with a corresponding aisle. In other words, in one form, the mounting holes 208 allow for a magnetic guideline 202 of the panel 200 to be precisely centered with the aisle centerlines of a storage structure 102. In addition, this alignment feature may be used to make installation easier and reduce installation mistakes by allowing panels 200 to only be installed in a certain orientation. For example, as shown in FIG. 9, the mounting holes 208 may be arranged so that a panel 200 may only be installed in one of two orientations, i.e., with a longer leg parallel to the end of a storage structure 102. In other words, there may be two sets of mounting holes 208 with each set arranged adjacent the edge of a longer leg, which allow the panel 200 to be mounted in one of two orientations. This mounting hole arrangement is asymmetric in that it does not allow the panel 200 to be mounted in the two other orientations, which reduces installation errors. Alternatively, as another example, the mounting holes 208 might be arranged so that the panel 200 may be installed in exactly one orientation. In one form, it is contemplated that these mounting holes 208 may be formed by a panel manufacturer at a separate location, prior to shipment and installation to form the floor 120 of a transit area 114.

[0047] FIG. 9 also shows two sets of fastener holes 210 arranged parallel to one another. In some forms, it is contemplated that these two sets of fastener holes 210 may be used as an alternative to the cleats 130 described above. This pattern of fastener holes 210 may allow for the use of standard self-tapping screws to fasten the panels 200 to the beams 122. Again, in one form, it is contemplated that these fastener holes 210 may be formed by a panel manufacturer prior to installation.

[0048] The panel 200 may also include features to aid navigation by mobile robots 108. For example, the panel 200 may include at least one fiducial marker 212 applied to the top surface of the panel 200. As shown in FIG. 9, in one form, there may be two fiducial markers 212 that are formed near the center of the panel 200. In this form, the two fiducial markers 212 are generally in a diagonal orientation relative to the horizontal and vertical magnetic guidelines 202. Further, in this form, they are in opposite, facing quadrants of the panel 200, as defined by the horizontal and vertical magnetic guidelines 202 and are generally symmetric about the center. This symmetric arrangement allows the panel 200 to be installed in one of two orientations (one orientation being 180 degrees relative to the other).

[0049] In one form, it is contemplated that grooves may be cut in the panel 200 during prefabrication and prior to installation of the panel 200. Then, after panel installation, fiducial markers in the form of fiducial magnets may be installed in these grooves. In other words, the fiducial markers 212 may be applied or formed after installation of the panel 200.

[0050] These fiducial markers 212 may be used as reference points to allow a mobile robot 108 to determine its location and to aid with navigation. It is generally contemplated that these reference points may be detected by imaging sensors of the mobile robots 108. In other words, the fiducial markers 212 are configured to facilitate determination of position and navigation by mobile robots traveling on the floor 120 of the transit area 114. Although one example of a type and arrangement of fiducial markers is shown, it should be understood that other types and arrangements may also be used.

[0051] Another feature that may be used as a navigational aid is an RFID tag 214. RFID tags 214 may be used in addition to, or as an alternative to, the fiducial markers 212. For example, as shown in FIG. 9, the top surface of the panel 200 includes markings 213 for the drilling of holes for the installation of RFID tag(s) 214. These markings may be arranged in a symmetric manner about the center of the panel 200 so as to allow the panel 200 to be installed in one of two orientations. Further, in one form, these markings are applied during prefabrication of the panels 200.

[0052] Further, as can be seen in FIG. 10, it is generally contemplated that an RFID tag 214 may be applied to a bottom, or underside, surface of the panel 200. In one form, holes are drilled through the panel 200 to allow the RFID tag 214 to be applied to the bottom surface after the panel 200 has been installed. The panel 200 may include at least one RFID tag 214 applied to a bottom surface of the panel 200. The RFID tag 214 is configured to facilitate determination of position and navigation by mobile robots traveling on the floor 120.

[0053] As stated above, the automated storage and retrieval system 100 may include transition plates 132. FIG. 11 is a top view of a portion of a panel 200 connected to a transition plate 132, and FIG. 12 is a partial perspective view of a panel 200 connected to a transition plate 132. In one form, the translation plate 132 is intermediate the panel 200 and a corresponding aisle 112 of a storage structure 102. In one aspect, it is intended to align the magnetic guidelines 202 of the panel 200 with the centerlines of the corresponding aisle 112. In one form, it is contemplated that the mobile robots 108 may be self-guided and / or rail-guided along the centerlines of the aisles 112 of the storage structure 102.

[0054] As can be seen in FIG. 11, the transition plate 132 is configured for attachment to the mounting holes 208 of the panel 200 for alignment of the transition plate 132 both with the panel 200 and with the corresponding aisle 112. It includes two tabs or extensions 133 with through holes to allow mounting and alignment of the transition plate 132 with the mounting holes 208 of the panel 200. In one form, the transition plate 132 allows the mobile robots 108 to traverse from a storage structure 102 to a transit area 114 across a smooth coplanar surface. It also may act as a transition between the slightly different elevations of the aisles 112 of the storage structure 102 and the panels 200 in the transit area 114. Further, it shares the same mounting holes 208 as the panel 200, thereby sharing an alignment feature with the panel 200. In addition, as can be seen in FIG. 11, in one form, it may be mounted between two beams 122 and two uprights 116.

[0055] The automated storage and retrieval system 100 may also include mounting brackets 134. FIG. 13 is a partial view showing mounting brackets 134 connecting beams 122 to uprights 116 at one end of a storage structure 102. In one form, each mounting bracket 134 couples a first end of each beam 122 to a corresponding end of a storage structure 102. The mounting brackets 134 may be used at both ends of a beam 122 to attach the beam to a first storage structure 102A at one end and to attach the beam 122 to a second storage structure 102B at the other end. Further, in one form, the beams 122 forming the frame portion 118 are connected to the support structure 102, while the panels 200 forming the floor 120 are connected to the beams 122. The mounting brackets 134 generally allow for the universal use of standardized beams 122 having the same size and features throughout the various transit area assemblies. As can be seen, FIG. 13 shows two types of mounting brackets 134A and 134B that may be used, but other types of brackets may also be used. In one form, the two types of mounting brackets 134A and 134B mount to different structures of the upright 116, which establishes desired load carrying assemblies.

[0056] FIG. 14 shows a process 300 for constructing an automated storage and retrieval system. It is generally contemplated that the process 300 may involve some or all of the components of the automated storage and retrieval system 100 and may involve some or all of the features of the panel 200. The above descriptions of the system 100 and the panel 200 are generally incorporated herein.

[0057] At block 302, a storage structure is provided with storage locations for storing totes containing goods. It is generally contemplated that the storage structure may include a plurality of pathways, in the form of aisles, with each storage location accessible by an aisle. In one form,it is contemplated that the storage structure is constructed prior to construction of a transit area adjacent the storage structure.

[0058] At block 304, mobile robots may be utilized that are configured to traverse the aisles of the storage structure. The mobile robots are configured to access storage locations to deposit or retrieve totes at the storage locations. It is generally contemplated that the mobile robots may be provided at any time during the process 300. For example, the mobile robots may be provided after construction of both the storage structure and the transit area are completed.

[0059] At block 306, prefabricated panel(s) are received with magnetic guidelines and having alignment features. In one form, it is contemplated that panels are received having several prefabricated features prior to installation of the panels. The panels may be pre-formed with at least one groove receiving compression fit metal material therein to form the one or more magnetic guidelines prior to installation of the floor. The panels may also include an alignment feature aligning the one or more magnetic guidelines in a predetermined manner with respect to a corresponding aisle configured for exit of mobile robots from the corresponding aisle to the panel. In one form, the alignment feature may include mounting holes at predetermined positions of the panels for receiving fasteners, which may establish one of two possible orientations of the panel during installation. Another prefabricated feature may include fastener holes to receive fasteners for attaching the panel to a support beam. Additionally, the panels may include markings indicating the locations of through holes for application of RFID tags following installation. Further, in one form, additional fiducial grooves may be cut in the top surface of the panel.

[0060] At block 308, a frame portion of a transit area is attached to the storage structure. In one form, the frame portion may be composed of support beams. One end of each support beam may be attached to a corresponding end of the storage structure, and more specifically, may be attached to an upright at an end of the storage structure. The beams may be attached to the storage structure by mounting brackets.

[0061] At block 310, the panel(s) are oriented in accordance with the alignment features. For example, the alignment features may be in the form of mounting holes that allow the panel to be oriented in one of two orientations. Once aligned, the panel may be affixed to the support beams by fasteners. At block 312, a floor of the transit area is installed composed of panels and supported by the frame portion. During installation, the panels may be aligned and affixed one by one to form the floor.

[0062] Following installation, it is contemplated that additional features may be applied to the panels. At block 314, fiducial markers may be applied to the panels following installation. In one form, these fiducial markers are formed by installing magnets in the fiducial grooves on the top surface of the panel. At least one fiducial marker may be applied to a panel following installation of the floor, and the at least one fiducial marker may be configured to facilitate determination of position and navigation by mobile robots traveling on the floor.

[0063] At block 316, RFID tags may be applied to the panels following installation. More specifically, at least one RFID tag may be applied to a panel following installation of the floor, and the at least RFID tag may be configured to facilitate determination of position and navigation by mobile robots traveling on the floor. These RFID tags may be applied to the bottom surfaces of the panels. In one form, through holes may be drilled at marked locations on the top surface to facilitate application of the RFID tags. These RFID tags may be applied in addition to, or as an alternative to, the fiducial markers.

[0064] At block 318, transition plate(s) may be aligned and mounted between panels and aisles following installation. In one form, the transition plates may each include an alignment feature, such as, for example, tabs / extensions with mounting holes that are aligned with the mounting holes of the panel. These transition plates allow mobile robots to travel from the storage structure to the transit area and vice versa.

[0065] Those skilled in the art will recognize that a wide variety of other modifications, alterations, and combinations can also be made with respect to the above-described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.

Claims

Claims1. An automated storage and retrieval system comprising: a first storage structure comprising a plurality of storage locations configured to store totes containing goods, the first storage structure comprising a first plurality of pathways, each storage location accessible by a pathway, the pathways configured to be traversed by a plurality of mobile robots, each mobile robot configured to access a storage location to deposit or retrieve a tote at the storage location; and a transit area adjoining the first storage structure providing access to mobile robots to enter or exit at least some of the pathways, the transit area comprising: a frame portion formed of a plurality of beams configured for coupling to the first storage structure; and a floor supported by the frame portion, the floor comprising a plurality of panels collectively defining the floor, at least one panel comprising one or more guidelines at predetermined locations of the at least one panel to facilitate movement of the mobile robots thereon.

2. The automated storage and retrieval system of claim 1, wherein the one or more guidelines comprise one or more magnetic guidelines and the at least one panel further comprises at least one groove configured to receive compression fit metal material therein to form the one or more magnetic guidelines.

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

4. The automated storage and retrieval system of claim 1, wherein the at least one panel further comprises an alignment feature configured to align the one or more guidelines in a predetermined manner with respect to a corresponding pathway configured for entry and exit of mobile robots between the corresponding pathway and the at least one panel.

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

6. The automated storage and retrieval system of claim 1, wherein the at least one panel comprises at least one fiducial marker applied to a top surface of the at least one panel, the at least one fiducial marker configured to facilitate determination of position and navigation by mobile robots traveling on the floor.

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

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

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

10. The automated storage and retrieval system of claim 9, further comprising: a second storage structure comprising a plurality of storage locations configured to store totes containing goods, the second storage structure comprising a second plurality of pathways, each storage location accessible by a pathway; and a second plurality of mounting brackets, each mounting bracket coupling a second end of each beam to a corresponding end of the second storage structure.

11. A panel for supporting mobile robots traveling on the panel, the panel comprising: one or more magnetic guidelines formed in a top surface of the panel at predetermined locations to facilitate movement of the mobile robots along the top surface; at least one groove formed in the top surface of the panel, the at least one groove configured to receive metal material therein to form the one or more magnetic guidelines; andan alignment feature configured to align the one or more magnetic guidelines in a predetermined manner with respect to a corresponding pathway configured for entry and exit of mobile robots between the corresponding pathway and the panel.

12. The panel of claim 11, wherein the alignment feature comprises at least two mounting holes at predetermined positions of the panel, the at least two mounting holes each configured to receive a fastener therein.

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

14. The panel of claim 11, further comprising: at least one fiducial marker applied to the top surface of the panel, the at least one fiducial marker configured to facilitate determination of position and navigation by mobile robots.

15. A method of constructing transit areas of automated storage and retrieval systems, the method comprising: coupling a frame portion of a transit area to a storage structure by coupling a plurality of beams to the storage structure, the storage structure comprising a plurality of storage locations configured to store totes containing goods, the storage structure comprising a plurality of pathways, each storage location accessible by a pathway the pathways configured to be traversed by a plurality of mobile robots, each mobile robot configured to access a storage location to deposit or retrieve a tote at the storage location, the transit area allowing mobile robots to enter or exit the pathways; and installing a floor supported by the frame portion, the floor formed by a plurality of panels collectively defining the floor, at least one panel comprising one or more guidelines at predetermined locations of the at least one panel to facilitate movement of the mobile robots thereon.

16. The method of claim 15, further comprising: receiving the at least one panel as prefabricated with at least one groove receiving compression fit metal material therein to form the one or more guidelines prior to installation of the floor.

17. The method of claim 15, further comprising: applying at least one fiducial marker to the at least one panel following installation of the floor, the at least one fiducial marker configured to facilitate determination of position and navigation by mobile robots traveling on the floor.

18. The method of claim 15, further comprising: applying at least one RFID tag to the at least one panel following installation of the floor, the at least one RFID tag configured to facilitate determination of position and navigation by mobile robots traveling on the floor.

19. The method of claim 15, further comprising: receiving the at least one panel with an alignment feature aligning the one or more guidelines in a predetermined manner with respect to a corresponding pathway configured for entry and exit of mobile robots between the corresponding pathway and the at least one panel.

20. The method of claim 19, wherein the alignment feature comprises at least two mounting holes at predetermined positions of the at least one panel, the at least two mounting holes each configured to receive a fastener therein.

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