Material handling system for automatic retrieval of sorted items

Abstract

The system includes a movable track for transporting items in cooperation with a storage system having storage locations for storing the items, a horizontal drive system operable for a vehicle to enter the movable track, elevate the track using a vertical drive mechanism, and drive the vehicle horizontally along a ground to bring the movable track to a position adjacent to the storage locations, actuating the vertical drive system to lower the movable track adjacent the storage system, actuating the vertical drive system to travel upwardly along the movable track to a raised position adjacent one of the storage locations in the storage system, and a transfer mechanism for transferring items between the vehicle and the storage locations while the vehicle is in the raised position.

Description

Claiming priority

[0001] This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 63 / 152,842, filed February 23, 2021, and U.S. Provisional Patent Application No. 63 / 208,956, filed June 9, 2021. The entire disclosures of each of the above-referenced applications are incorporated herein by reference. [Technical field]

[0002] FIELD OF THE DISCLOSURE Embodiments of the present invention relate generally to automated material and item handling systems that may be used in warehouse, storage and / or distribution environments. [Background technology]

[0003] Sorting and retrieving items to fulfill orders can be tedious and time consuming. Many large organizations have vast storage areas in which items are stored. Manually storing and retrieving items from hundreds or thousands of storage areas requires significant effort. Automated picking has been developed in many areas to reduce labor costs and improve customer service by shortening the time it takes to fulfill customer orders. However, known systems for automatically handling materials can be very expensive or have limitations that prevent their effectiveness. Thus, a need exists for automated storage and / or retrieval of items in a variety of material handling applications. Additionally, once the items of an order have been sorted into bins or other containers, it would be desirable to have a system that automatically removes the container with the completed order and transports the container to another location. Summary of the Invention [Problem to be solved by the invention]

[0004] SUMMARY OF THE PRESENT EMBODIMENT The present invention addresses the shortcomings of known systems and provides a system for automatically acquiring groups of items sorted by a sorting system.

[0005] The present invention also provides an apparatus and method for identifying containers in a sorting system that require shaking to organize the contents, and a system for automatically shaking the identified containers to organize the contents of the containers.

[0006] The present invention also provides a material handling system including a containment assembly having a plurality of containers in a plurality of storage locations, and a controller that identifies when one of the containers is full. The system further includes an retrieval system configured to retrieve the full container from the storage location and to transport the container from the storage location. The acquisition system includes a transport means configured to transport the container from the storage location onto the acquisition system. [Brief description of the drawings]

[0007] So that the recited features of the present invention can be understood in detail, a more particular description of the foregoing summary of the invention will now be made by reference to the embodiments illustrated in the appended drawings. However, the accompanying drawings show only an embodiment of the present invention and are not intended to limit the scope thereof, which may allow for other embodiments having similar effect.

[0008] [Figure 1A] FIG. 1 is a perspective view of a warehouse automation system.

[0009] [Figure 1B] FIG. 2 is a partial perspective view of the material handling system.

[0010] [Diagram 2] 1C is a top view of the material handling system shown in FIG. 1B with the automatic acquisition system in a first position.

[0011] [Diagram 3]3 is a top view of the material handling system shown in FIG. 2 with the automatic acquisition system in a second position.

[0012] [Figure 4] 3 is a top view of the material handling system shown in FIG. 2 with the automatic acquisition system in a third position.

[0013] [Diagram 5] FIG. 4 is a side view of the material handling system shown in FIG.

[0014] [Figure 6] FIG. 1C is a perspective view of a sorting system of the material handling system shown in FIG.

[0015] [Figure 7] FIG. 7 is a plan view of the sorting system shown in FIG. 6.

[0016] [Figure 8] FIG. 7 is a partial side view of the sorting system shown in FIG. 6.

[0017] [Figure 9] FIG. 7 is an enlarged perspective view of a portion of the sorting system shown in FIG. 6.

[0018] [Figure 10] FIG. 7 is a plan view of a sorting vehicle of the sorting system shown in FIG. 6.

[0019] [Figure 11] FIG. 11 is a side view of the sorting vehicle shown in FIG.

[0020] [Figure 12] FIG. 1C is a perspective view of an acquisition vehicle of the acquisition system of the material handling system shown in FIG.

[0021] [Figure 13] FIG. 13 is a plan view of the capture vehicle shown in FIG.

[0022] [Figure 14] FIG. 13 is an end view of the capture vehicle shown in FIG.

[0023] [Figure 15] FIG. 13 is a side view of the acquisition vehicle shown in FIG. 12 .

[0024] [Figure 16] FIG. 1C is an end view of the acquisition system of the material handling system shown in FIG.

[0025] [Figure 17] FIG. 17 is a side view of the acquisition system shown in FIG. 16.

[0026] [Figure 18] FIG. 17 is an enlarged cutaway view of a portion of the acquisition system shown in FIG. 16.

[0027] [Figure 19] FIG. 17 is an enlarged cutaway view of a portion of the acquisition system shown in FIG. 16.

[0028] [Figure 20] FIG. 17 is a side view of the acquisition system of FIG. 16 with the assembly in a raised position.

[0029] [Figure 21] FIG. 17 is a partial perspective view of the acquisition system of FIG. 16 with the acquisition vehicle in a raised position.

[0030] [Figure 22] FIG. 17 is a partial side view of the carriage and track of the acquisition system shown in FIG. 16.

[0031] [Diagram 23] 23 is a partial side view of the carriage and track shown in FIG. 22 in combination with the acquisition vehicle shown in FIG. 12.

[0032] [Figure 24] FIG. 23 is a front view of the carriage shown in FIG. 22 in combination with a container.

[0033] [Diagram 25]FIG. 24 is an enlarged partial view of the vehicle and carriage shown in FIG. 23;

[0034] [Figure 26] FIG. 17 is a partial enlarged view of the acquisition system shown in FIG. 16.

[0035] [Figure 27] FIG. 23 is a perspective view of the carriage shown in FIG. 22.

[0036] [Figure 28] FIG. 28 is a partially enlarged perspective view of the carriage shown in FIG. 27.

[0037] [Figure 29] FIG. 28 is a plan view of the carriage shown in FIG. 27.

[0038] [Diagram 30] 28 is a perspective view of the carriage shown in FIG. 27 as viewed from the underside of the carriage.

[0039] [Diagram 31] FIG. 28 is a partially cutaway plan view of the carriage shown in FIG. 27.

[0040] [Diagram 32] FIG. 1C is an enlarged perspective view of a portion of the material handling system shown in FIG.

[0041] [Diagram 33] 17 is an enlarged partial plan view of the connection between the sorting system shown in FIG. 6 and the acquisition system shown in FIG. 16.

[0042] [Diagram 34] FIG. 34 is a partial enlarged side view of the connection portion shown in FIG. 33 in a non-connected position.

[0043] [Diagram 35] FIG. 35 is a partially enlarged side view of the connection portion shown in FIG. 34 in the connection position.

[0044] [Diagram 36]FIG. 7 is a perspective view of a sorting station of the sorting system shown in FIG. 6.

[0045] [Figure 37] 37 is an enlarged partial perspective view of the sorting station shown in FIG. 36 with the retainer in an open position.

[0046] [Figure 38] FIG. 38 is a partially enlarged side view of the retainer shown in FIG. 37.

[0047] [Figure 39] 23 is an enlarged partial side view of the carriage shown in FIG. 22 in combination with the sorting station of the sorting system shown in FIG. 6.

[0048] [Figure 40A] 38 is a side view of the retainer shown in FIG. 37, with the retainer in an open position.

[0049] [Figure 40B] FIG. 40B is a side view of the retainer shown in FIG. 40A, with the retainer in an actuated position.

[0050] [Figure 40C] FIG. 40B is a side view of the retainer shown in FIG. 40A with the retainer in a closed position.

[0051] [Diagram 41] 17 is a partial perspective view of the acquisition system shown in FIG. 16 in combination with a container holder.

[0052] [Diagram 42] FIG. 42 is a perspective view of a portion of the container holder shown in FIG. 41 .

[0053] [Figure 43A] 42 is an enlarged partial cutaway plan view of the acquisition system shown in FIG. 41 with the container holder in an unlatched position.

[0054] [Figure 43B] FIG. 43B is an enlarged partial cutaway plan view of the acquisition system shown in FIG. 43A with the container holder partially in an actuated position.

[0055] [Figure 43C] FIG. 43B is an enlarged partial cutaway plan view of the acquisition system shown in FIG. 43A with the container holder in an active position.

[0056] Although the system and method are described herein in examples using several embodiments and exemplary drawings, the system and method for performing inventory control tasks using accessory modules having corresponding functions for each part of the inventory control task is not limited to the embodiments or drawings. The drawings and detailed description are not intended to limit the embodiments to any particular form. Rather, the intention is to cover all modifications, equivalent arrangements and alternative arrangements falling within the spirit and scope of the systems and methods for performing portions of inventory control tasks using accessory modules having corresponding functionality as defined by the appended claims. The headings used herein are for organizational purposes only and are not meant to limit the scope of the specification or the claims. The word "may", as used herein, is used in a permissive sense (i.e., may) rather than a mandatory sense (i.e., must). Similarly, the word "including" means including but not limited to. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0057] DETAILED DESCRIPTION Various embodiments of a method and apparatus for performing inventory control tasks in an inventory control system are described. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of claimed subject matter. However, claimed subject matter may be practiced without these specific details. In other instances, methods, apparatus or systems that would be known to one of ordinary skill in the art have not been described in detail to avoid obscuring the claimed subject matter.

[0058] The detailed descriptions which follow are presented in part in terms of algorithms and symbolic representations based on binary digital signals stored within a memory of a particular apparatus or special purpose computing device or computing platform. In the context of this specification, the term specific device or the like may include a general purpose controller that is programmed to perform particular functions pursuant to instructions from program software. Algorithmic descriptions and symbolic representations are examples of techniques used by those skilled in the signal processing or related arts to convey the substance of their work to others skilled in the art. An algorithm, as used here, and generally, is a self-consistent sequence of operations or similar signal processing leading to a desired result. In this context, operations or processing include physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It is sometimes convenient, principally for reasons of common usage, to refer to such signals as bits, data, values, elements, symbols, characters, terms, numbers, numerals, or the like. However, all of these terms are to be associated with appropriate physical quantities and are merely convenient labels.

[0059] Unless otherwise indicated, as will be apparent from the discussion that follows, throughout this specification, discussions using terms such as "processing," "computing," "determining," and the like refer to specific apparatus operations or processes, such as a special purpose computing device or similar special purpose electronic computing device. Thus, in the context of this specification, a special purpose computing device or similar special purpose electronic computing device is capable of manipulating or transforming signals that are typically represented as physical electronic or magnetic quantities in a memory, register, or other information storage, transmission device, or display device of the special purpose computing device or of a similar special purpose electronic computing device.

[0060] Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like parts.

[0061] 1A and 1B, a material handling apparatus is shown generally at 10. The material handling device 10 is configured to sort the items into separate groups and to retrieve the items once grouping is complete. The material handling device 10 optionally includes a sortation system 50 that sorts items into multiple locations, such as multiple bins 45 . The material handling device 10 also includes an acquisition system 300 that automatically acquires the bins 45 from the sortation system storage locations 80 once the items have been sorted into the bins 45 . The acquisition system 300 may also be configured to replace a full container with an empty container at the storage location 80 . Additionally, the acquisition system 300 may be configured to transport the full containers to a work station or conveyor system so that processing can be performed on the full containers, such as preparing them for shipment.

[0062] The material handling equipment 10 may be integrated into an overall warehouse automation system 5, which may include one or more systems for sorting and acquiring items. The warehouse automation system 5 may include an input conveyor 30 that supplies containers 45 to each material handling device 10 . For example, input conveyor 30 may transport containers full of items to be sorted to an input of sortation system 50 . Additionally, the warehouse automation system 5 may include an output conveyor 32 that transports the containers away from the sortation system 50 after they are full of sorted items. In particular, each sorting apparatus 10 may include an acquisition system 300 capable of transferring containers 45 from the sorting system 50 to an output conveyor 32 so that completed containers with sorted items can be transported to another area (such as an area where the sorted items are prepared for shipment).

[0063] The warehouse automation system 5 may include a restricted access fence 35 surrounding the area including the sortation system 50 and the acquisition system 300. The exclusion barrier 35 may be designed to prevent human operators from entering the area in which the acquisition system 300 operates. Additionally, the exclusion fence 35 may include one or more maintenance entrances, such as an access gate 36 . The doorway 36 may include a sensor that sends a signal if the door is open. In response to a signal indicating that one of the doors of the entryway 36 is open, the sorting system 50 may control one or more elements, such as the acquisition system 300, to render the acquisition system 300 inoperative.

[0064] Although the sorting and acquiring material handling device 10 is shown as part of an overall warehouse automation system 5, such embodiment is shown for purposes of illustrating an exemplary embodiment. Therefore, it should be understood that various elements such as the input conveyor 30, the output conveyor 32 and the exclusion barrier 35 are not essential to the operation of the warehouse automation system 5.

[0065] The various components of the material handling system 10 and / or warehouse automation system (such as the sortation system 50 and the acquisition system 300) may be controlled by a central controller 20, such as a microcontroller. The central controller 20 may receive signals from various elements, such as sensors, and control various aspects of the warehouse automation system based on the signals received from the various components. Based on the signals received from sorting system 50 and acquisition system 300, central controller 20 sends control signals to control various elements of sorting system 50 and acquisition system 300, as described below. The central controller 20 may also store data regarding the locations of various items obtained from the warehouse automation system. Additionally, central controller 20 may include data regarding the identity of items to be acquired (eg, the number of items to fulfill a customer order), along with data regarding the quantities of such items. In this manner, central controller 20 may control and coordinate the operation of the various components to schedule and coordinate the retrieval and processing of various items from storage locations 80 .

[0066] The central controller 20 may also be in communication with a warehouse management system (WMS), which may provide information regarding the items being processed, such as the items included in various orders, the sequence of the orders, and other similar parameters. The central controller 20 may control various elements of the warehouse automation system based on the data received from the WMS.

[0067] Optional sortation system 50 may be any of a variety of systems configured to sort items into various containers, such as bins 45 . In the illustrated embodiment, sortation system 50 incorporates a number of transport vehicles that transport items along a track 100 to bins 45 . Each bin 45 may be stacked to accommodate multiple items transported by multiple delivery vehicles. Sorting system 50 includes a plurality of bins 45 . The container 45 may be in any of a variety of configurations. For example, in the illustrated embodiment, the containers 45 are arranged in a plurality of columns or rows.

[0068] The acquisition system 300 is configured to acquire containers 45 from the sortation system 50 as each container 45 becomes full. Even if the container 45 is not physically completely full (ie, even if there is still some free space within the container 45), the container 45 may still be considered full. Alternatively, the acquisition system 300 may consider the container 45 to be full when a threshold is reached at which the acquisition system 300 considers the container 45 to be physically full. Additionally, acquisition system 300 may consider a container 45 to be full once all items for an order have been delivered to the container 45 . For example, if an order requires 10 items and all 10 items are delivered to container 45, container 45 may be considered to be fully loaded, regardless of how much free space exists in container 45. Thus, upon receiving a signal indicating that the containers 45 in the sortation system 50 are full, the central controller 20 controls the acquisition system 300 to acquire the full containers 45 from the sortation system 50 . Upon acquiring the container 45, the acquisition system 300 transports the fully loaded container 45 to an input / output area, such as a work station or conveyor. Optionally, the acquisition system 300 transports the empty container 45 to the storage location 80 from which the full container 45 was removed.

[0069] As shown in FIGS. 1-5 and described below, the acquisition system 300 may include a movable track 400 and an acquisition vehicle 310 configured to move the movable track 400. The acquisition vehicle 310 is configured to lift and move the movable track 400 to align it with the fully loaded container 45 . The acquisition vehicle 310 may then climb the movable track 400 and transfer the fully loaded container 45 onto the acquisition vehicle 310 . The acquisition vehicle 310 may then descend the movable track 400 and drive the fully loaded container 45 to the input / output station where the fully loaded container 45 may be transferred to the input / output station. Optionally, the acquisition system 300 may be configured to lift the movable track 400 while the acquisition vehicle 310 carries the fully loaded container 45 so that the acquisition vehicle 310 can transport the movable track 400 and fully loaded container 45 to an input / output station. At the input / output station, the acquisition vehicle 310 lowers the movable track 400 to the ground and lifts the fully loaded container 45 up the movable track 400 to the transfer location. Once up to the transfer location, the acquisition vehicle 310 may be configured to transport the fully loaded container 45 to the transfer location. After delivering the full bin 45 to the input / output station, the acquisition vehicle 310 may lower and drive the moveable track 400 back to the sortation system 50 to acquire another full bin 45 .

[0070] Optionally, acquisition system 300 may be configured to store one or more containers 45 such that multiple containers 45 can be acquired and transported simultaneously to an input / output station. Similarly, the acquisition system 300 may store multiple empty containers 45 such that the multiple empty containers 45 can be delivered to multiple empty storage locations 80 within the sortation system 50 .

[0071] It should be understood that the various items and subassemblies throughout acquisition system 300 may be used alone or in combination with material handling systems that are constructed or operate differently than the sorting system shown in the figures and described below. <Sorting system>

[0072] The material handling system may include a sortation system 50 for sorting items. Sorting system 50 may take any number of forms incorporating multiple storage locations 80 . For example, sortation system 50 may employ one or more sorting elements, such as vehicles, moveable arms, or other automated elements. Whatever sorting equipment is used, the items are conveyed to a series of output containers, such as bin 45.

[0073] Throughout this description, the term "vessel" includes any type of container capable of housing one or more items. Preferably, the container 45 is configured to accommodate a variety of items such that multiple items can be stacked within the container 45 . For example, the container 45 may include an opening to allow items to be dropped into or ejected from the sorting element into the container 45 .

[0074] The containers 45 may be arranged in any of a variety of configurations. Preferably, however, the containers 45 are arranged in a grid or array. For example, the containers 45 may be organized into a number of columns or rows.

[0075] The sorting system below describes the sorting station in detail. However, this is merely an exemplary sorting system. The details of the sorting system are optional features that can be changed or eliminated depending on the needs of a particular application.

[0076] 6-9, a sorting system 50 is shown. Sortation system 50 includes a pair of spaced apart sorting storage racks 70, 72 defining an aisle 75 therebetween. Multiple sortation vehicles 200 may operate within an aisle 75 . In particular, sortation vehicle 200 may move along a track 100 disposed within aisle 75, as described below.

[0077] The sortation system 50 shown in Figures 6-9 includes optional locations for supplying items. This supply station is called induction station 60. The induction station 60 may determine an identifying characteristic of the item being fed into the material handling system 10 . The identifying characteristic may be any of a variety of characteristics, such as a product number or a UPC code. The distinguishing characteristics may be determined manually, such as by an operator. However, in this embodiment, induction station 60 includes scanning station 62, which may include multiple scanners, such as optical scanners in the form of bar code scanners, digital cameras, and the like. The induction station 60 may include a conveyor that transports the items past a scanner, or an operator may manually scan the items before feeding them into the sortation system.

[0078] The induction station 60 includes a conveyor, such as a conveyor belt or a number of rollers, for continuously transporting the items to a loading station where the items are loaded onto the sorting vehicle 200. Multiple items may be loaded onto each sortation vehicle 200 . However, in this embodiment, each item is loaded onto a separate sortation vehicle 200, which transports the item to one of the storage locations 80.

[0079] Although the configuration of induction station 60 may vary, details of induction station 60 are described in US Pat. No. 10,494,192. The entire disclosure of US Pat. No. 10,494,192 is incorporated herein by reference. Additionally, induction station 60 is not a required component and aspects of the present invention may be utilized in sorting systems that do not include induction station 60.

[0080] 6-7, sorting system 50 will now be described in greater detail. The sortation system 50 includes a number of storage locations 80 for retrievably storing items. In one configuration, items are transported to the storage locations 80 by multiple automated sorting vehicles 200 . The storage location 80 is operable to store items such that an automated retrieval device can retrieve the items from the storage location 80 . For example, storage bins 45 may be located at each storage location 80, and sortation system 50 may transport items to different storage bins 45 to fulfill customer orders. Once the sortation system 50 has delivered all items required for an order to a particular storage container 45, the storage container 45 may be removed from storage location 80 and replaced with an empty storage container 45, as described below.

[0081] Storage locations 80 may be positioned in a variety of orientations. For example, with reference to FIGS. 6-7, sortation system 50 may include two opposing sortation storage racks, a front sortation storage rack 70 and a rear sortation storage rack 72 . The front sorting storage rack 70 and the rear sorting storage rack 72 are spaced apart from each other to form an aisle 75 between the sorting storage racks. Optionally, the front sorting storage rack 70 and the rear sorting storage rack 72 may be connected by a number of cross brackets interconnecting the sorting storage racks. In particular, a plurality of upper cross brackets may extend between the tops of the sorting storage racks and a plurality of cross braces may extend between the bottoms of the sorting storage racks, thereby connecting and spacing the sorting storage racks together to provide aisles 75.

[0082] The track 100 may take any of a variety of configurations depending on the application. One embodiment is shown in FIG. 8 and includes a closed circulation path having multiple rows. Similarly, the material handling system 10 may be configured as a series of rows connected by vertical tracks. Additionally, material handling system 10 may be an open track rather than a closed circulation path. It should therefore be understood that the circular path configuration depicted is by way of example only, and that the track 100 may take any of a variety of forms.

[0083] As shown in FIG. 8, the track 100 optionally includes a horizontal upper rail 114 and a horizontal lower rail 116 . A number of vertical sections 112 extend between an upper horizontal section 114 and a lower horizontal section 116 . During transport, the sortation vehicle 200 travels up a pair of vertical sections 112 from a loading dock to an upper rail 114 . Sortation vehicle 200 then travels along upper rail 114 in the direction of travel indicated by arrow T1 until it reaches a queue having an appropriate bin 45 or destination area. The sortation vehicle 200 then travels downward along two front vertical columns and two parallel rear columns until it reaches the appropriate bin 45 or destination, and then discharges the items into the bin 45 or destination area. The sortation vehicle 200 then continues down the vertical section 112 until it reaches the lower horizontal section 116 . The sorting vehicle 200 then follows the lower rail back to the loading station.

[0084] With reference to FIGS. 6-7, the track 100 includes a forward track 105 and an aft track 110 . The front track 105 and the rear track 110 are parallel tracks that cooperate to guide the sorting vehicle 200 along the track 100 . In the description of track 100 , front track 105 and rear track 110 are similarly configured opposing tracks that support front and rear wheels 220 of sorting vehicle 200 . In particular, in this embodiment, the rear track 110 has the same configuration as the front track 105 . Thus, unless otherwise noted below, a description of a portion of either the forward track 105 or the aft track 110 also applies to the opposing forward track 105 or aft track 110.

[0085] The details of the trajectory may be substantially similar to those described in US Pat. No. 7,861,844. The entire disclosure of US Pat. No. 7,861,844 is incorporated herein by reference.

[0086] Referring to FIG. 9, the track 100 includes a drive surface 120 that positively engages the sorting vehicle 200 to enable the sorting vehicle 200 to travel along the track 100 . The drive surface 120 may be of any of a variety of configurations for engaging with drive elements of the sortation vehicle 200 . In particular, the drive surface 120 may be configured to mate or interlock with a drive element of the sorting vehicle 200 . One example of a drive surface 120 includes a series of teeth that form a rack that engages with wheels of a sortation vehicle 200, as described further below. Similarly, the track 100 may include a series of recesses or detents that cooperate with corresponding elements, such as sprockets or other elements protruding from a wheel. Thus, the term “positively engaged” refers to an engagement between the drive surface 120 and the drive elements of the sorting vehicle 200 that prevents the drive elements from sliding along the track 100 .

[0087] Optionally, the track 100 may also include a guide surface 122 in the form of a generally planar surface adjacent the drive surface 120 . For example, the drive surface 120 may extend across approximately half of the track 100 and the guide surface 122 may extend across the remaining half of the track 100 . As shown in FIG. 9, the drive surface 120 may be formed on an inner wall of the track 100, and the opposing outer wall may be a generally flat surface parallel to the guide surface 122 of the inner wall.

[0088] As mentioned above, the track 100 may include a number of vertical sections 112 extending between horizontal upper and lower rails 114 and 116 . An intersection may be formed at each segment of the track 100 where one of the vertical sections 112 intersects with one of the horizontal sections. For example, each intersection may include a pivotable gate 125 having a smoothly curved inner race and a flat outer race with a drive surface that corresponds to the drive surface 120 of the track 100 . The gate 125 may pivot between a first position and a second position. In the first position, the gate 125 may be closed such that the straight outer race of the gate 125 is aligned with the straight outer branch of the intersection. In the second position, the gate 125 may be open such that the curved inner race of the gate 125 is aligned with the curved branch of the intersection.

[0089] The central controller 20 is configured to control the operation of the gates 125 depending on the position of each sorting vehicle 200 and the route traveled by each sorting vehicle 200. Specifically, the central controller 20 is configured to send a signal to each gate to operate the gate into either an open or closed position. <Sorting vehicle>

[0090] As mentioned above, the sorting system may include any of a variety of sorting elements. The sorting systems described herein utilize one or more sorting vehicles 200. The sorting vehicle 200 will be described in detail with reference to FIGS. Each sorting vehicle 200 may be a semi-automatic vehicle having an on-board drive system that includes an on-board power source. Each sorting vehicle 200 optionally includes mechanisms for loading and unloading the items it transports. Sorting vehicle 200 is shown in US Pat. No. 7,861,844, the entire disclosure of which is incorporated herein by reference.

[0091] Additionally, as described in more detail below, sorting vehicle 200 includes a mechanism for driving sorting vehicle 200 along track 100. The drive mechanism may include any of a variety of elements. In this embodiment, the drive mechanism includes a number of wheels 220 that engage the track 100 .

[0092] Additionally, sorting vehicle 200 optionally incorporates a mechanism for loading items onto sorting vehicle 200 and discharging the items from sorting vehicle 200 into one of the bins 45. The loading / unloading mechanism 210 may be specially tailored for a particular application. For example, the sortation vehicle 200 may include a loading surface upon which items may be placed. The loading surface 210 may be a static loading surface, and the system may include components operable to load items onto and unload items from the loading surface. Alternatively, the loading surface may be operable. For example, the loading surface may be one or more horizontal belts. The belts may be selectively operable to transport items onto the sortation vehicle 200 . Similarly, the belt may be selectively operable to eject items from the belt. In this embodiment, the loading / unloading mechanism 210 is shown as one or more conveyor belts extending along the top surface of the sortation vehicle 200 . The conveyor belt is reversible. Driving the belt in a first direction displaces items toward the rear end of the sortation vehicle 200. Driving the belt in a second direction displaces items toward the forward end of the sortation vehicle 200.

[0093] The sorting vehicle 200 may include a conveyor motor mounted on the underside of the sorting vehicle 200 that drives a conveyor belt. The conveyor belt may be trained around front rollers at the front end of the sorting vehicle 200 and rear rollers at the rear end of the sorting vehicle 200. A conveyor motor may be connected to the front roller to drive the front roller, thereby moving the conveyor belt.

[0094] The sorting vehicle 200 may include multiple wheels. As shown in Figures 10-11, each sorting vehicle 200 may include four wheels 220: two front wheels and two rear wheels. The terms forward and backward refer to the track on which the wheels travel and not to the direction in which the sorting vehicle 200 travels. Specifically, the front wheels travel on front track 105 and the rear wheels travel on rear track 110 .

[0095] The wheels 220 are mounted on two parallel spaced axles 215, 216 such that two wheels are positioned along the front end of the sorting vehicle 200 and two wheels are positioned along the rear end of the sorting vehicle 200. Specifically, wheels 220 a and 220 b are attached to leading axle 215 , while wheels 220 c and 220 d are attached to trailing axle 216 . Axle 215 is referred to as the leading axle because axle 215 typically leads and axle 216 typically follows when sorting vehicle 200 moves horizontally. However, sorting vehicle 200 may also be reversed such that axle 216 is the leading axle and axle 215 is the trailing axle. Therefore, it should be understood that the terms leading and trailing do not imply any requirement or restriction on the orientation of the sorting vehicle 200 and its direction of travel.

[0096] Each wheel 220 may include a drive element 222 that cooperates with the drive surface 120 of the track 100 . The drive element 222 may be any of a variety of components configured to mate with the drive surface 120 of the track 100 . For example, the drive element 222 may be a rotatable element such as a gear or sprocket. In this embodiment, the drive element 222 is a gear, such as a pinion gear having a number of teeth.

[0097] Each wheel 220 includes a drive element 222 and optionally a guide element. The guide elements guide the wheels along the track area where the track 100 transitions from one direction to another. The guide elements may support a portion of the load of the sorting vehicle 200 . According to one embodiment, the guide element may be a roller, such as idler roller 224 . The roller 224 may be disposed coaxially with and adjacent to the drive element 222 . While drive element 222 engages drive surface 120 , idler rollers 224 may engage and rotate along track 100 to drive sortation vehicle 200 along track 100 .

[0098] Optionally, the drive elements 222 of the sorting vehicle 200 are configured such that a first drive element on a first axle engages the front track 105 and a second drive element on the first axle engages the rear track 110. Similarly, a first drive element on the second axle engages the front track 105 and a second drive element on the second axle engages the rear track 110 . Thus, two spaced apart drive elements 222 , such as gears, engage the front track 105 and two spaced apart drive elements 222 , such as gears, engage the rear track 110 .

[0099] The sorting vehicle 200 includes an on-board motor that drives wheels 220 . More specifically, a drive motor is operatively connected to the axles to rotate the axles 215, 216, which in turn rotates the wheel gears 222.

[0100] Sorting vehicle 200 may be powered from an external power source, such as contacts along the rails, which provide the power necessary to drive sorting vehicle 200. However, in this embodiment, the sorting vehicle 200 includes an on-board power supply that provides the necessary power for both the drive motor and the conveyor motor. Additionally, in this embodiment, the power source is rechargeable. The power source may include a power source such as a rechargeable battery, but in this embodiment the power source is comprised of one or more ultracapacitors.

[0101] A central controller 20 may control the operation of the sorting vehicles 200 to direct the sorting vehicles 200 to the appropriate bins 45 . In particular, the central controller 20 is configured to receive data from various sensors located along the track and on the sortation vehicle 200, in addition to receiving data regarding the appropriate bin 45 to which the item should be delivered. Based on the data received by the central controller 20 , the central controller 20 directs the sorting vehicle 200 to the appropriate bin 45 . At the appropriate bin 45 , the sorting vehicle 200 discharges the item into that bin 45 . The central controller 20 may send various control signals to control the sorting vehicles 200 . For example, the central controller 20 may send control signals that actuate the gates to direct the path that the sorting vehicle 200 will follow. Additionally, the central controller 20 may send signals to selectively advance sortation vehicles 200 based on the location of other sortation vehicles 200 in the system. <Acquired vehicle>

[0102] 12-15 show details of an acquisition vehicle 310 that can be incorporated into the acquisition system 300. FIG. As mentioned above, if the system incorporates an acquisition vehicle 310, the construction of the acquisition vehicle 310 may vary. Thus, it should be understood that each of the features of the acquisition vehicle 310 discussed below are optional features that may be varied or omitted depending on the application.

[0103] The acquisition vehicle 310 may be an autonomous system that includes an on-board power source for powering the acquisition vehicle 310 . The acquisition vehicles 310 may also include a communications system for wirelessly transmitting and receiving control signals between each acquisition vehicle 310 and a control element such as central controller 20 . In this manner, the acquisition vehicle 310 may receive control signals regarding the location from which to acquire the item and the location to which the acquisition vehicle 310 delivers the item.

[0104] The acquisition vehicle 310 shown in FIG. 12 includes a horizontal drive assembly 320 that drives the acquisition vehicle 310 in a horizontal direction. The horizontal drive assembly 320 may be configured to drive the acquisition vehicle 310 along a track or along an open horizontal surface, such as a floor. For example, one option for the horizontal drive assembly 320 includes a number of rotatable elements, such as wheels or rollers. One or more drive mechanisms may be provided to rotate the rotatable elements. Additionally, the rotatable element may rotate left or right to steer the acquisition vehicle 310 .

[0105] Alternatively, as shown in Figures 13 to 15, the acquisition vehicle 310 may have a horizontal drive 320 formed of a number of rollers 322, 323, 324 rotatable about a first axis, such as an axle. Additionally, rollers 322, 323, 324 may be constrained to rotate about a single axis. For example, in the embodiment shown in FIGS. 13-15, the horizontal drive 320 includes a pair of center rollers 324 and first and second sets 322 and 323 of outer rollers. A first set of outer rollers 322 are located in front of the central rollers and a second set of outer rollers 323 are located behind the central rollers 324 . The outer rollers 322, 323 may include rollers spaced apart along the length of the horizontal axle such that each set of outer rollers includes a first roller 322 on one side of the capture vehicle 310 and a second roller 322 on the opposite side of the capture vehicle 310, as shown in FIG. 14. Additionally, as shown in FIG. 14, each set of outer rollers may include a pair of rollers 323 on each side of the capture vehicle 310.

[0106] As mentioned above, the acquisition vehicle 310 may have any of a variety of steering mechanisms for controlling the direction of the acquisition vehicle 310 . For example, optional steering mechanisms include a zero-turn mechanism that allows the acquisition vehicle 310 to turn without substantially moving forward. Optionally, the zero-turn mechanism provides a means for rotating the acquisition vehicle 310 about a vertical axis extending through the acquisition vehicle 310 .

[0107] The zero-turn mechanism includes a linkage mechanism that allows the wheels or rollers on one side of the capture vehicle 310 to turn at a different speed than the wheels or rollers on the opposite side of the capture vehicle 310. Optionally, the linkage allows the wheels or rollers on one side of the capture vehicle 310 to rotate in a different direction than the wheels or rollers on the opposite side of the capture vehicle 310. In this manner, the zero-turn mechanism changes the direction of travel and steers the acquisition vehicle 310 by varying the speed and / or rotational direction of the wheels on one side of the acquisition vehicle 310 relative to the speed and / or rotational direction of the wheels on the opposite side of the acquisition vehicle 310.

[0108] Optionally, acquisition system 300 may include one or more guides to guide or align acquisition vehicle 310 as it moves. For example, the guide may include grooves or depressions, and the acquisition vehicle 310 may include corresponding guiding elements that cooperate with the guide to control the movement of the acquisition vehicle 310 . An example of a guide element is follower 326 . The follower 326 may be any element configured to engage or cooperate with a guide. In this embodiment, the acquisition vehicle 310 includes a central follower 326 that includes a rotatable element, such as a bearing, that rotates about a vertical axis. The center follower 326 engages a recess in the guide to constrain the horizontal movement of the acquisition vehicle 310 .

[0109] In addition to the horizontal drive mechanism 320, the acquisition vehicle 310 may also include a vertical drive mechanism 340 for driving the acquisition vehicle 310 vertically along the track. In particular, as described above, the system may include a guide mechanism, such as a track 420, disposed adjacent the support structure. The vertical drive mechanism 340 may be configured to cooperate with the track 420 to drive the acquisition vehicle 310 vertically.

[0110] 12-15 show a vertical drive mechanism 340 that includes a plurality of rotatable vertical drive gears 345. It should be noted that vertical drive mechanism 340 may include any of a number of drive mechanisms for driving capture vehicle 310 vertically. With reference to FIG. 14, the vertical drive mechanism 340 may include a drive gear 345 that rotates about a horizontal axis that is perpendicular to the horizontal axis of rotation of the horizontal drive mechanism 320 . Specifically, optionally, the acquisition vehicle 310 includes a pair of vertical drive gears 345 spaced apart from each other, with a first vertical drive gear tooth of the vertical drive gear 345 protruding outward from a first side of the acquisition vehicle 310 and a second vertical drive gear tooth of the vertical drive gear 345 protruding outward from a second side of the acquisition vehicle 310, as shown in FIG. 14 . The first vertical drive gear and the second vertical drive gear 345 may be driven synchronously. Additionally, as shown in FIG. 13, the acquisition vehicle 310 may include two pairs of vertical drive elements spaced apart along the length of the acquisition vehicle 310. Specifically, optionally, the acquisition vehicle 310 includes a first pair of vertical drive elements 345 at a first end of the acquisition vehicle 310 and a second pair of vertical drive elements 345 at a second end of the acquisition vehicle 310.

[0111] 12 and 13, the tracks 420 of the acquisition system 300 may be configured such that the track on the first side is spaced from the track on the second side by a distance corresponding to the spacing between the first set of vertical drive elements 345 and the second set of vertical drive elements 345. In this manner, the first vertical drive element 345 may cooperate with the first track to drive the capture vehicle 310 above the first track, while the second vertical drive element 345 may cooperate with the second track to drive the capture vehicle 310 above the second track. Optionally, the two vertical drive elements 345 are driven synchronously so that the acquisition vehicle 310 maintains a horizontal orientation as the acquisition vehicle 310 moves from horizontal to vertical motion.

[0112] Vertical drive mechanism 340 may optionally be configured such that the width of vertical drive mechanism 340 remains substantially constant as acquisition vehicle 310 transitions from horizontal to vertical movement. In this manner, the vertical drive mechanism 340 does not need to narrow or expand outward in width to transition from horizontal to vertical drive.

[0113] The acquisition vehicle 310 may also include an optional transport mechanism for transporting items between the acquisition vehicle 310 and a destination, such as the storage location 80 .

[0114] For example, the transfer mechanism 350 may operate to transfer items between a loading surface of the acquisition vehicle 310 and one of a number of destination area storage locations 80 . Optionally, a loading surface is defined by the outer surfaces of a number of rollers 356, as shown in FIG.

[0115] The transfer mechanism 350 may be any of a variety of mechanisms for loading items onto the acquisition vehicle 310 and unloading items from the acquisition vehicle 310 into one of the storage areas. Additionally, the transfer mechanism 350 may be specially tailored for a particular application. In this embodiment, the transfer mechanism 350 includes one or more displaceable elements configured to engage items stored in the storage location 80 and pull the items onto the acquisition vehicle 310 . More specifically, in this embodiment, acquisition vehicle 310 includes one or more displaceable elements configured to move toward and releasably engage container 45 within storage location 80 . After the displaceable elements engage the container 45 , each displaceable element is displaced away from the storage location 80 , thereby pulling the container 45 onto the acquisition vehicle 310 .

[0116] The displaceable element of the transfer mechanism 350 may be any of a variety of items, such as a bar, rod, or another element configured to engage an item, such as the container 45 . For example, with reference to FIGS. 12-15, a transfer mechanism 350 includes rollers 356 that form a surface for receiving a container 45 . In particular, rollers 356 may be drive rollers such that rollers 356 can rotate to selectively transfer container 45 onto or off of acquisition vehicle 310 . Additionally, the transport mechanism 350 may include one or more displaceable pins 352 and a drive element for displacing the pins 352 . For example, optionally, the transport mechanism 350 includes two drive elements in the form of an endless carrier, such as a drive belt or drive chain 354 . Optionally, each pin 352 protrudes or extends inwardly toward the longitudinal centerline of the acquisition vehicle 310 . The transfer mechanism 350 is configured to cooperate with one of the containers 45 and to releasably engage the container 45 . For example, in this embodiment, pin 352 is configured to mate with a recess in container 45 such that transfer mechanism 350 can engage container 45 . However, the transfer mechanism 350 may include any of a variety of elements that engage with items being transferred onto or off of the acquisition vehicle 310 .

[0117] The acquisition vehicle 310 includes one or more drive elements for driving the transfer mechanism 350 . Optionally, acquisition vehicle 310 includes one or more motors that drive transfer mechanism 350 . For example, one or more motors of the vehicle drive system may drive the chain 354 to selectively move the chain 354 and pin 352 toward or away from a storage location 80 (such as one of the bins 45 of the sortation system 50).

[0118] When the acquisition vehicle 310 approaches the storage location 80 to acquire the container 45 , the chain 354 may drive the displaceable pin 352 toward the storage location 80 so that the pin 352 fits under a groove or notch in the bottom of the container 45 . The acquisition vehicle 310 moves slightly upward until the pin 352 is located within a groove or notch in the container 45 . Chain 354 then reverses rotation so that pin 352 moves away from storage location 80 . The pin 352 engages the container 45 within the notch so that when the pin 352 moves away from the storage location 80 , the pin 352 pulls the container 45 onto the surface of the acquisition vehicle 310 . In this manner, the transfer mechanism 350 is operable to retrieve items from the storage location 80 . Similarly, to transfer an item to storage location 80 , chain 354 of transport mechanism 350 drives pin 352 toward storage location 80 until the item is located at storage location 80 . The capture vehicle 310 then releases the container 45 by moving downward to disengage the pin 352 from the container 45 .

[0119] The acquisition vehicle 310 may include a separate drive element for driving the transfer mechanism 350 . Alternatively, the transfer mechanism 350 may be interconnected with one of the horizontal or vertical drive elements of the acquisition vehicle 310 . In particular, the transfer mechanism 350 may be coupled to one of the drive systems such that the drive system is selectively operable to drive the acquisition vehicle 310 and the transfer mechanism 350 .

[0120] For example, optionally, the transport mechanism 350 may be connected to one of the horizontal drive systems using a selectable connection, such that in a first orientation, the drive system drives the acquisition vehicle 310 horizontally and in a second orientation, the drive system drives the transport mechanism 350. An optional clutch mechanism may be selectively engaged and disengaged to initiate and terminate the transfer of power from the motor of the horizontal drive system to the transfer mechanism 350, thereby allowing the second drive system to operate independently of the transfer mechanism 350.

[0121] The configuration of the acquisition vehicle 310 may vary, but details of the acquisition vehicle 310 operable with the acquisition system 300 are provided in U.S. Patent Application Publication No. 2021 / 0047117. The entire disclosure of U.S. Patent Application Publication No. 2021 / 0047117 is incorporated herein by reference. Additionally, it should be noted that aspects of the present invention may be utilized in systems that do not include an acquisition vehicle 310 .

[0122] The acquisition vehicle 310 may be powered from an external power source, such as a contact along a continuous charging rail, or using an inductive power transfer coil, which provides the power necessary to drive the acquisition vehicle 310. However, in this embodiment, the acquisition vehicle 310 includes an on-board power supply that provides the necessary power for both the first drive motor and the motor that drives the second drive system. The on-board power source may be rechargeable. In this regard, the power source may include a power source such as a rechargeable battery, a stack of ultracapacitors as the capacitor, or a combination thereof. For example, ultracapacitors can accept very high amperage when recharging. By using high currents, ultracapacitors can be recharged in a very short time, in seconds or minutes, as opposed to the hours required to charge a proper battery. However, an automated process of replacing discharged batteries with recharged batteries as part of the process of operating the acquisition vehicle 310 may also be employed.

[0123] If a charging rail is used, each acquisition vehicle 310 may include one or more contacts for recharging the power source. In this embodiment, the acquisition vehicle 310 may include a number of brushes, such as copper brushes, that are spring loaded so that the brushes are biased outward. As described further below, the brushes cooperate with a charging rail to recharge the power source.

[0124] Optionally, the charging rail is a conductive strip connected to a power source. Charging contacts on the acquisition vehicle 310 engage the conductive strips to recharge the ultracapacitors. Specifically, biasing elements on the brushes bias the brushes outwardly toward the charging contacts. Electricity flowing through the charging contacts provides high amperage, low voltage electricity that can recharge the ultracapacitors in a matter of seconds or minutes, depending on the amount of power consumed during a series of inventory control tasks or subtasks.

[0125] A processor in each acquisition vehicle 310 controls the operation of the acquisition vehicle 310 in response to signals received from the central controller 20 . Additionally, acquisition vehicle 310 includes a wireless transceiver so that acquisition vehicle 310 can continually communicate with central controller 20 as it travels along track 420 . Alternatively, in some applications it may be desirable to incorporate multiple sensors or indicators along the route traveled by the acquisition vehicle 310. The acquisition vehicle 310 may include a reader for sensing the sensor signals and / or indicators, as well as a central processor for controlling operation of the acquisition vehicle 310 in response to the sensors or indicators. <Obtained column>

[0126] As mentioned above, sortation system 50 may include multiple storage locations 80 containing multiple bins 45 . For example, storage locations 80 may be configured as sorting storage racks having an arrangement of horizontal rows and / or vertical columns. The acquisition system 300 may include a vertical track 420 disposed along one or more sortation storage racks. For example, the vertical track 420 may be fixedly connected to the sortation system 50 . The vertical track 420 may be configured to guide the acquisition vehicle 310 vertically such that the fully loaded container 45 can be acquired by transporting the acquisition vehicle 310 up and down along the vertical track 420 . The vertical track 420 may be formed as one or more acquisition columns 400 positioned adjacent to the storage locations 80 . For example, the acquisition track 420 may include one or more acquisition columns 400 on a vertical track 420 configured to cooperate with the acquisition vehicle 310 so that the acquisition vehicle 310 can ascend to the storage location 80 of the sortation system 50.

[0127] As shown in FIGS. 2-5 and 16-20, the acquisition system 300 may include a movable track 400 configured to guide the acquisition vehicle 310 to acquire the fully loaded container 45. Because the containers 45 may be located in multiple vertically spaced storage locations 80, the movable track 400 may be formed as a vertical track so that the acquisition vehicle 310 can climb the movable track 400. Optionally, the movable track 400 includes multiple tracks forming a row, and the acquisition vehicle 310 is configured to travel vertically within the acquisition row to acquire the fully loaded containers 45 . Additionally, the queue may be configured to allow acquisition vehicle 310 to ascend and descend movable track 400 while acquisition vehicle 310 is positioned within acquisition queue 400, as described below.

[0128] 16-21, a movable acquisition train configured to cooperate with acquisition vehicle 310 is indicated generally at 400. The acquisition train 400 may be an elevator mechanism, such as an elevator, that includes a powered element for lifting the acquisition vehicle 310 . Alternatively, the structure may include guides or tracks configured to cooperate with the capture vehicle 310 to elevate the capture vehicle 310 without the use of an external power mechanism. For example, the acquisition train 400 may include a track 420 configured to cooperate with the vertical drive mechanism 340 of the acquisition vehicle 310 . The acquisition vehicle 310 may be driven up the track 420 to lift the acquisition vehicle 310 to the desired storage location 80 within the sortation system 50 .

[0129] The capture queue 400 may be movable such that it can be moved to a different storage location 80 or a different capture queue within the sortation storage racks 70,72. Further, optionally, the acquisition queue 400 is configured to cooperate with the acquisition vehicle 310 such that the acquisition vehicle 310 can lift the acquisition queue vertically and transport the acquisition queue horizontally along a path toward the storage location 80 (along a path toward one of the rows of sorting storage racks 70, 72). In this manner, the acquisition vehicle 310 may be configured to move the movable track 400 vertically or horizontally to a desired location and then climb the movable track 400 to acquire a fully loaded container 45 .

[0130] 16-21, the movable acquisition column 400 will now be described in more detail. The acquisition train 400 includes a number of orbital elements that guide the acquisition vehicle 310 . Additionally, the acquisition train 400 may include an optional transport assembly separate from the acquisition vehicle 310 . The optional transfer assembly is operable to engage one of the containers 45 in the storage location 80 and transfer the container 45 onto the acquisition vehicle 310 . The acquisition train 400 may also include a storage mechanism for storing one or more containers 45 while the acquisition vehicle 310 either acquires a full container 45 or transports an empty container 45 to an empty storage location 80.

[0131] The movable track 400 includes support structures that form vertical rows. The row includes a plurality of spaced apart vertical posts 410a, b, c, d. The pillars are generally parallel to one another and spaced apart to form columns having a length and width corresponding to the length and width of the capture vehicle 310 . In particular, the vertical pillars are spaced apart such that pillars 410 a and 410 b form an opening at least as wide as the width of acquisition vehicle 310 . Pillar 410c is parallel to pillar 410a and is spaced from pillar 410a by a distance at least approximately equal to the length of capture vehicle 310. Pillar 410d is parallel to pillars 410b and 410c and forms an opening with pillar 410c that forms a discharge opening for transferring items between acquisition vehicle 310 and storage location 80. The movable row 400 may include a number of horizontal rails 412 interconnecting posts 410a,b,c,d and / or cross brackets connecting the posts to form a free-standing structure.

[0132] The movable train 400 may also include structure that cooperates with the vertical drive mechanism 340 of the capture vehicle 310 to enable the capture vehicle 310 to climb upwardly. For example, the movable train may include one or more track elements configured to cooperate with the capture vehicle 310 to enable the capture vehicle 310 to climb upwardly. Optionally, the track elements may include a number of teeth spaced vertically along the vertical track 420 . The vertical track 420 may have uniformly pitched teeth for cooperation with the climbing vertical drive gear 345 of the capture vehicle 310 . Although the vertical track 420 is described as having a plurality of teeth, the vertical track 420 may be any of a variety of structures configured to allow the acquisition vehicle 310 to climb upwardly. Thus, the term vertical track 420 may refer to any guide configured to cooperate with the vertical track 420 to facilitate vertical displacement of the acquisition vehicle 310.

[0133] The vertical track 420 may be connected to the structure 400 in a variety of orientations depending on the configuration of the vertical drive mechanism 340 of the acquisition vehicle 310 . In this embodiment, the vertical track 420 is oriented to cooperate with the vertical drive gear 345 of the acquisition vehicle 310 . Optionally, a vertical track 420 is connected to the structure 400 to cooperate with the acquisition vehicle 310 to enable the acquisition vehicle 310 to ascend vertically while maintaining an orientation relative to the horizontal. In other words, the vertical track 420 may be connected to a structure such that the acquisition vehicle 310 can climb the vertical track 420 without tilting relative to the horizontal.

[0134] For example, a first track element 420a may be attached to the inside of post 410a and a second track element 420b may be attached to the inside of post 410b. The two vertical tracks 420 a , 420 b may be spaced apart by a distance corresponding to the distance between the drive gears 345 of the acquisition vehicle 310 . Similarly, a third and fourth raceway may be mounted inside posts 410c and 410d and spaced apart a distance corresponding to the distance between the drive gears 345. Thus, the vertical drive gears 345 of the acquisition vehicle 310 may be driven synchronously so that the acquisition vehicle 310 can climb the vertical track 420 while maintaining a horizontal orientation so as not to tilt relative to the horizontal.

[0135] 16-18, the movable track 400 is shown with the acquisition vehicle 310 in a lowered position, such that the acquisition vehicle 310 rests on a horizontal surface, such as a floor. The movable track 400 may remain in the same horizontal plane as the acquisition vehicle 310 . 19-20, the movable track 400 is shown in a raised position where the acquisition vehicle 310 has raised the movable track 400. Specifically, when the acquisition vehicle 310 is located in the acquisition row, actuating the vertical drive mechanism 340 in a first direction causes the vertical drive mechanism 340 to drive the movable track 400 upward, thereby lifting the movable track 400. As the acquisition vehicle 310 ascends the movable track 400 , the horizontal drives 322 , 323 , 324 are operable to horizontally displace the acquisition vehicle 310 to move the movable track 400 horizontally.

[0136] Additionally, when the capture vehicle 310 is located in the row, driving the vertical drive mechanism 340 in a second direction causes the capture vehicle 310 to lower the moveable track 400 if the moveable track 400 is raised. Alternatively, if the movable track 400 is supported on a floor or similar horizontal surface, driving the vertical drive mechanism 340 in a second direction causes the acquisition vehicle 310 to travel upward along the vertical track 420. Similarly, if the capture vehicle 310 is at a position above the ground on the vertical track 420, driving the vertical drive mechanism 340 in a first direction will cause the capture vehicle 310 to travel vertically downward until it reaches the ground.

[0137] The vertical drive mechanism 340 of the acquisition vehicle 310 may be configured such that the vertical drive gears 345 are displaced inwardly to reduce the distance between the multiple vertical drive gears 345 . In this way, as the capture vehicle 310 enters the queue, the vertical drive gear 345 can be moved inward to provide a gap between the vertical track 420 and the vertical drive gear 345 . Alternatively, as discussed above, the vertical drive gears 345 may be mounted on a shaft such that the axis of rotation of each vertical drive gear 345 is substantially parallel to the direction of horizontal movement. Additionally, the axes of rotation of the vertical drive gears 345 may be substantially fixed such that the lateral distance between each pair of vertical drive gears 345 is substantially fixed. Thus, to enter the row, the teeth of vertical drive gear 345 are aligned with the teeth of vertical track 420 such that the teeth of vertical drive gear 345 pass through the teeth of vertical track 420 .

[0138] Referring to FIG. 18, the vertical track 420 and the vertical drive gear 345 may be aligned such that the vertical drive gear 345 does not collide or contact the vertical track 420 when the vertical drive gear 345 moves relative to the vertical track 420. Specifically, the vertical track 420 and the vertical drive gear 345 may be configured to allow the teeth of the vertical drive gear 345 to pass the teeth of the vertical track 420 as the acquisition vehicle 310 enters the acquisition train 400 . For example, the spacing between the teeth of the vertical track 420 may be sufficient to provide sufficient clearance for the teeth of the vertical drive gear 345 to pass through the gaps between the teeth of the vertical track 420 as the vertical drive gear 345 moves horizontally along a line parallel to the axis of rotation of the vertical drive gear 345. Details of the vertical track 420 and the vertical drive gear 345 are described in U.S. Patent Application Publication No. 2021 / 0047117.

[0139] Additionally, optionally, the lower section 425 may have a sloped pitch line such that the clearance between adjacent teeth gradually decreases as one moves up the height of the lower section 425. In other words, the clearance 428 between adjacent teeth is greatest at the bottom of the lower section 425 and least at the top of the lower section 425, with the clearance gradually decreasing from the maximum to the minimum.

[0140] The vertical drive mechanism 340 , configured as described above, may optionally be configured to pass through an opening in the track 420 of the acquisition column 400 such that the vertical drive mechanism 340 is aligned with the vertical track 420 . After the vertical drive mechanism 340 is aligned with the vertical track 420, the vertical drive mechanism 340 is positioned to cooperate with the vertical track 420 to raise and / or climb the acquisition column 400 in cooperation with the vertical track 420 as described above.

[0141] Optionally, the movable track 400 may incorporate one or more connectors or retainers 440 that releasably connect the movable track 400 to the sorting system 50 . Optionally, the sorting system 50 may include a mating connector 150 that matingly engages with a connector 440 on the movable track 400 . The connectors 150, 440 may be any of a variety of mechanical connectors. In this embodiment, connector 150 may be configured as a hanging member that cooperates with connector 440 and is configured to connect the two connectors by vertically displacing the acquisition column relative to sorting system 50. Optionally, the two connectors are released by vertically displacing the acquisition queue relative to the sorting system 50 in opposite directions.

[0142] 2-5 and 36-37, the details of the releasable connector or retainer 440 will be described in greater detail. The retainer 440 is configured to cooperate with the upper connector 150 of the sorting system 50 to align the acquisition row 400 relative to the sorting system 50 . The retainer 440 optionally includes one or more pins that fit into recesses or grooves in the upper connector 150 . For example, the upper connector 150 may include a first V-groove 152 for aligning the acquisition frame in a first direction and a second V-groove 154 for aligning the acquisition frame in a second direction perpendicular to the first direction. As shown in Figures 34-35, the V-groove may have rounded bases so that the groove forms a U-shape. In any event, the upper connector 150 includes a groove with tapered, converging walls that guide the retainer 440 into a specific position.

[0143] In this manner, one or more connectors 440 optionally interconnect the acquisition queue 400 with the sortation system 50 to prevent lateral displacement of the acquisition queue relative to the sortation storage racks 70 , 72 of the sortation system 50 . Note that the row 400 may remain on the floor. However, if the bed height is not constant, the acquisition column may not be vertically aligned with the storage location 80 / vessel 45. In this embodiment, the top of the acquisition column can be held in a defined vertical position by a holder 440, as described above. In particular, the retainer 440 may be configured to position the row 400 vertically relative to the sorting station. Thus, the retainer 440 may be configured to position the row at a predetermined location relative to the sort station 80 / bin 45.

[0144] The acquisition array 400 may also include electrical contacts 430 that provide an electrical connection between the acquisition array 400 and an external power source. For example, the acquisition queue 400 may include contacts that are releasably connectable to electrical contacts of the sorting system 50 . Additionally, the acquisition queue 400 may have a number of electrical contacts for electrically connecting the acquisition queue 400 to an external power source wherever the acquisition queue 400 is located, such as at the sorting system 50, an input / output station, or other fixed location. In this manner, the acquisition system 300 is electrically connected to an external power source when positioned at any of the various fixed locations within the automated warehouse system. Thus, while the acquisition system 300 is located at a fixed location and electrically connected to an external power source, the external power source can provide power for the acquisition system 300 to operate while it is operating at the fixed location. Additionally, the acquisition system 300 charges a rechargeable power storage system that is on-board the acquisition system 300 .

[0145] For example, contacts 430 on the acquisition queue 400 may releasably connect with electrical connectors in the sorting station to provide power to the acquisition queue. The acquisition train may include separate electrical contacts 430 that releasably connect with the acquisition vehicle 310 when the acquisition vehicle 310 is located in the acquisition train. In this manner, while the acquisition vehicle 310 is operating in the acquisition line, the acquisition vehicle 310 remains electrically connected to the power source of the sorting system 50, eliminating the need to limit the power drain of a rechargeable storage device on board the acquisition vehicle 310, for example, when driving the acquisition line up, driving the carriage, and optionally powering functions of the acquisition system 300 (such as a pump that provides suction to the vacuum up 500). It should be noted that the pump that provides suction to the vacuum cups and other electrical components of the acquisition system 300 may be connected directly to the electrical contacts 430 such that such electrical components do not need to be electrically connected to the acquisition vehicle 310.

[0146] The capture system configured as described above may optionally include a movable track 400 that cooperates with part of the capture system to enable the capture vehicle 310 to capture the container 45 from the elevated storage location 80. In particular, the acquisition vehicle 310 may be controlled by a controller, such as central controller 20, to guide the acquisition vehicle 310 into alignment with an opening configured to receive the acquisition vehicle 310. Optionally, the movable track includes a movable train, and the acquisition vehicle 310 is aligned with an opening for entering the interior of the acquisition train. The acquisition vehicle 310 may then enter the queue through the opening. The acquisition vehicle 310 may be driven to align with a vertical track 420 in the acquisition row such that the drive mechanism of the acquisition vehicle 310 engages the track 420 . For example, optionally, acquisition vehicle 310 includes a vertical drive mechanism 340 that cooperates with vertical track 420 .

[0147] Once the vertical drive mechanism 340 of the acquisition vehicle 310 is aligned with the vertical track 420, the system may control the vertical drive mechanism 340 to drive the vertical drive mechanism 340 in a first direction that raises or lifts the movable track 400 above the surface supporting the acquisition vehicle 310. Once the movable track 400 is raised, the acquisition vehicle 310 may be driven horizontally to move the movable track 400 to another location. Optionally, a horizontal drive system 320 of the acquisition vehicle 310 is controlled to drive the acquisition vehicle 310 . For example, the acquisition vehicle 310 may be driven toward a structure such as sortation storage racks 70,72 such that the openings of the movable rows are aligned with the storage locations 80 of the sortation storage racks 70,72.

[0148] In addition to moving the movable track 400 , optionally, the acquisition vehicle 310 is configured to climb the movable track 400 . For example, the movable track 400 may include a vertical track 420 extending vertically upward, and when the acquisition row is positioned on the ground adjacent to one of the sorting storage racks 70, 72, the acquisition vehicle 310 may be driven vertically upward along the vertical track 420 by driving the vertical drive mechanism 340 in a second direction. As shown in FIGS. 20-21, the acquisition vehicle 310 may travel vertically upward until it is aligned with the opening of the acquisition queue and an open storage location 80 of one of the sortation storage racks 70,72. Once the acquisition vehicle 310 is aligned with the open storage location 80 , the acquisition vehicle 310 may transfer an item, such as a container 45 , from the storage location 80 onto the acquisition vehicle 310 . In this manner, the acquisition vehicle 310 is operable to travel the movable track 400 , climb the vertical track 420 , and acquire a fully loaded container 45 from the storage location 80 . <Transport Assembly>

[0149] As mentioned above, the acquisition vehicle 310 may include a transport mechanism 350 , such as a transport pin 352 or a transport roller bed 356 , for transporting items, such as the containers 45 , onto the acquisition vehicle 310 . Additionally, with reference to FIG. 21, it may be desirable to incorporate a separate transfer assembly configured to retrieve container 45 from storage location 80. A separate transfer assembly 450 may be connectable to the acquisition vehicle 310 such that the transfer assembly 450 remains connected to the acquisition vehicle 310 when the acquisition vehicle 310 disengages from and moves away from the acquisition train. Optionally, as described below, the transfer assembly 450 may be configured to be retained within the acquisition queue such that the acquisition vehicle 310 can releasably engage and disengage from the transfer assembly 450 when entering and exiting the acquisition queue.

[0150] With reference to FIG. 22, an acquisition row 400 is shown with a transport assembly 450 disposed in a lower position within the acquisition row 400 . The transfer assembly 450 is positioned at an elevation above the earth's surface that is greater than the elevation of the acquisition vehicle 310 . In this manner, as the acquisition vehicle 310 enters the moving train 400 , the acquisition vehicle 310 travels underneath the transfer assembly 450 . When the four vertical drive gears 345 of the acquisition vehicle 310 are aligned with the vertical tracks 420 in the row 400 , the acquisition vehicle 310 is aligned with the transfer assembly 450 . Driving the acquisition vehicle 310 upwardly causes the acquisition vehicle 310 to operatively engage the transfer assembly 450 . As the acquisition vehicle 310 continues to travel upward, it lifts the transfer assembly 450 upward so that the acquisition vehicle 310 and transfer assembly 450 move together.

[0151] The transfer assembly 450 may include any of a variety of elements configured to extend to engage the container and pull the container onto the acquisition vehicle 310. In this embodiment, the transport assembly 450 includes a carriage 460 having a pair of side walls 462, 463, as shown in FIG. Side walls 462 and 463 are spaced apart wide enough to accommodate the width of the receptacle 45 or container to be acquired. The side walls 462, 463 are connected by an end wall 465 to form a generally U-shaped configuration having an open end through which containers or receptacles 45 are transferred between the acquisition vehicle 310 and the storage area 80.

[0152] The transfer assembly 450 may include a movable transfer head 470 configured to move along the length of the carriage 460 to transfer the container 45 between the acquisition vehicle 310 and the storage location 80. For example, as shown in FIG. 28, the side walls 462 , 463 of the carriage 460 may include a plurality of elongated guide rails 474 that extend along the length of the side walls 462 , 463 of the carriage 460 . The guide rails 474 on the first side wall are parallel to the guide rails 474 on the second side wall to provide a guide surface for the transfer head 470 as it moves between the retracted and extended positions. The transfer head 470 may include a number of guide wheels or rollers 476 that run on guide rails 474 to provide a rotational engagement between the transfer head 470 and the carriage 460 .

[0153] The transfer head 470 is movable between a retracted position and an extended position. In the retracted position, the transfer head 470 is adjacent or abuts the end wall 465 of the carriage 460 . In the extended position, the transfer head 470 is adjacent the ends of the side walls 462, 463 at the open end of the carriage 460 and spaced from the end wall 465 so that the transfer head 470 is positioned for operative engagement with the container 45 in the storage location 80.

[0154] Although the transfer head 470 may be independently powered, in this embodiment the transfer head 470 is driven by the acquisition vehicle 310 . Specifically, one of the displaceable elements of the acquisition vehicle 310 may cooperate with the transfer head 470 to drive the transfer head 470 between the extended and retracted positions. Power for the transfer head 470 may be provided from any of the various moving elements of the acquisition vehicle 310. For example, the transfer head 470 may include elements that engage with the transfer mechanism 350 of the acquisition vehicle 310 .

[0155] 23 and 25-28, an embodiment is shown in which the transport mechanism 350 of the acquisition vehicle 310 cooperates with and drives a transport head 470. A recess 520 extends across the width of the transfer head 470 . The recess 520 is configured to engage with the transfer pin 352 of the acquisition vehicle 310 . Specifically, the recess 520 has a length that is substantially the same as the distance from the transfer pin 352 on one side of the capture vehicle 310 to the transfer pin 352 on the other side of the capture vehicle 310 .

[0156] The carriage 460 is positioned within the acquisition row 400 such that the recesses 520 are positioned vertically above the transfer pins 352 when the acquisition vehicle 310 enters the acquisition row 400, as shown in Figures 23 and 25. As the acquisition vehicle 310 travels upward and engages the transfer assembly 450 , the transfer pins 352 of the acquisition vehicle 310 move into engagement with the recesses 520 of the transfer head 470 . When the transfer pin 352 is positioned within the groove of the transfer head 470, driving the transfer mechanism 350 of the acquisition vehicle 310 in a first direction drives the transfer head 470 toward the extended position, and driving the transfer mechanism 350 of the acquisition vehicle 310 in a second direction drives the transfer head 470 toward the retracted position.

[0157] The transfer head 470 may include one or more retraction mechanisms configured to engage and hold the container 45 for pulling the container 45 onto the acquisition vehicle 310. The retraction mechanism illustratively includes a movable arm or latch 490 configured to engage a flange on the container 45 . For example, container 45 may include a handle having a flange that covers a recess in the end of container 45 . The latch 490 may be configured to shift upwardly into the handle and latch onto the container 45, as shown in FIG.

[0158] The latch 490 may be connected to an associated mechanism that displaces the latch 490 between an upper position and a lower position. For example, referring to FIG. 22, before the acquisition vehicle 310 engages the transfer assembly 450, the latch 490 is shown in a lowered position. The latch 490 is connected to a four-bar linkage 492 having a downwardly extending actuator link 494 . As the acquisition vehicle 310 moves upward and engages the actuator link 494, the actuator link 494 engages the surface of the acquisition vehicle 310 such that the acquisition vehicle 310 drives the actuator link 494 upward. The four-bar linkage 492 is configured such that upward displacement of the actuator link 494 causes upward displacement of the latch 490 .

[0159] Alternatively, or in addition to the latch 490 , the transfer head 470 may include one or more vacuum cups 500 for engaging the container 45 . Specifically, the vacuum cup 500 may be connected to a pump 505 . The vacuum cup 500 is pressed against the end wall of the container 45 at the storage location 80 to form a seal. The vacuum pump 505 applies suction to the vacuum cup 500 such that the vacuum cup 500 holds the container 45 .

[0160] Although the above description describes the transfer head 470 having two separate retraction mechanisms, it should be understood that the transfer head 470 may include only a single retraction mechanism. Additionally, the transfer head 470 may include any number of various retraction mechanisms, as desired.

[0161] The transfer head 470 operates as follows. The acquisition vehicle 310 vertically climbs the acquisition queue, aligning the acquisition vehicle 310 with the full container 45 to be acquired. The transfer head 470 is actuated by driving the transfer mechanism 350 of the acquisition vehicle 310 in a first direction, which drives the transfer head 470 along the length of the side walls 462, 463 of the carriage 460 towards the extended position. In the extended position, the retraction mechanisms 390, 500 engage the fully loaded container 45. Once the retraction mechanisms 390, 500 engage the container 45, the transfer mechanism 350 of the acquisition vehicle 310 drives in reverse to drive the transfer head 470 towards the retracted position. As the transfer head 470 moves to the retracted position, the transfer head 470 pulls the fully loaded container onto the acquisition vehicle 310 .

[0162] The containment bins 45 may be oriented at an angle to the horizontal so that as items are sorted into the bins 45, the items move toward the front of the bins 45. Thus, to ensure that container 45 does not fall out of storage location 80 , storage location 80 may include a container retainer for retaining container 45 in storage location 80 .

[0163] 36-40C, the storage location 80 may be in the form of a flat surface, such as a shelf 82. The shelf 82 may be sloped downward relative to the horizontal. A displaceable stop 84 may be located at the front end of shelf 82 to prevent container 45 from moving out of shelf 82 . Thus, the stop 84 prevents the container 45 from inadvertently falling off the front end of the shelf 82 .

[0164] The stop 84 is displaceable between a raised position and a lowered position. In the raised position, the stop 84 engages the container 45 to prevent movement of the container 45 relative to the shelf 82 . In the lowered position, the container 45 is freely movable along the shelf 82 .

[0165] Stop 84 could be a simple lever, but in this embodiment stop 84 is a compound mechanism having an actuating arm connected to stop 84 . The actuation arm 90 is pivotable about a pivot axis and has a first end configured to engage the transfer head 470 to actuate the stop 84 . The actuator arm 90 has a second end 94 having a flange configured to engage the stop 84 . The stop 84 may be a pivotable arm that extends across the width of the shelf 82 . The stop 84 may have a downwardly projecting extension that forms a first engagement surface 87 and a second engagement surface 88 . Additionally, the stop 84 may pivot about a pivot axis 95 . Additionally, multiple biasing elements may bias the stop 84 toward the raised position.

[0166] 38 and 40A-40C, the operation of stop 84 will be described. As the transfer head 470 is displaced toward the extended position, an actuation surface, such as surface 472 of the transfer head 470 engages the actuation arm 90 of the stop 84 . The transfer head 470 displaces the actuation arm 90 from a first position shown in FIG. 40C to a second position shown in FIG. 40A. As the actuator arm 90 is displaced from the first position to the second position, the second end 94 of the actuator arm 90 engages the second engagement surface 88 of the stop arm 84, driving the stop 84 to the lowered position. Once the stop 84 is lowered, the transfer head 470 pulls the container 45 onto the acquisition vehicle 310, as described above. As the transfer head 470 moves away from the storage location 80 , the surface 472 of the transfer head 470 disengages from the actuator arm 90 . A biasing element biases the actuating arm 90 toward the first position such that the second end of the actuating arm 90 engages the first engagement surface 87 or flange 87 of the stop 84, driving the stop 84 to the raised position.

[0167] Thus, in addition to extending to engage container 45 in storage location 80 , transfer head 470 can actuate stop 84 to release container 45 from storage location 80 .

[0168] It may be desirable to acquire multiple full containers 45, store the containers 45 in a acquisition queue, and then transport all of the full containers 45 at once by driving the queue to an input / output station. Thus, with reference to Figures 5 and 41-43C, the system may include a vessel holder 600 that holds the vessels 45 in the acquisition row. Specifically, the container holder 600 may include a plurality of spatula or finger members 610, 612 displaceable between a retracted position and an extended position. In the retracted position, the spatula members 610 , 612 are retracted and disengaged from the container 45 . In the extended position, as shown in FIG. 5, the spatula members 610 , 612 form projections below a lip or flange that extends outwardly from the upper edge of the container 45 . In this manner, the spatula members 610, 612 hold the container 45 in the queue so that the acquisition vehicle 310 can acquire the container 45, and the container holder 600 can lift the container 45 in the queue so that it can be retained. The acquisition vehicle 310 can then be lowered and the container 45 released from the acquisition vehicle 310 so that the acquisition vehicle 310 can acquire another container 45.

[0169] The container holder 600 includes a pair of sides 605 and 606 on either side of the row 400, as shown in FIG. The first side 605 and the second side 606 are of substantially the same configuration. The first side 605 is shown in FIG. As shown in FIG. 42, a connecting arm 615 connects the first spatula member 610 to the second spatula member 612 . In addition, a drive arm 618 connects the first spatula member 610 to an actuator 620 . Actuator 620 includes a recess or pocket for engaging actuator 540 on transfer head 470 .

[0170] 43A-43C, the container holder actuator 540 includes a pivotable arm 542 having a roller at a distal end 544 that engages the container holder actuator 620. The actuating movable arm 542 also includes a driven roller 546 that is configured to retract and extend the pivotable arm 542 in accordance with the surface profile. Specifically, as shown in FIGS. 43A-43C, driven roller 546 follows cam surface 550 having receding surface 552, extending surface 554, angled extending surface 556, and angled receding surface 558. As the transfer head 470 transitions from the retracted position to the extended position, the container holder actuator 540 is actuated to extend the pivotable arms 542 outwardly, actuating the spatula members 610, 612 to rotate the spatula members 610, 612 from the retracted position to the extended position.

[0171] In the preceding description, the acquisition system 300 has been described as being used to acquire a full load of containers 45 from the sortation system 50 . Additionally, the acquisition system 300 may be used to operate a vessel 45 that is not fully loaded. For example, it may be desirable to shake container 45 to arrange items within container 45 to provide more space to receive additional items. The container 45 can be shaken in a manner similar to the process of obtaining a fully loaded container 45. Specifically, the capture vehicle 310 can be driven near a container 45 that has been identified as needing to be shaken. A transfer mechanism 350 operable to engage a fully loaded container 45 and transfer the fully loaded container 45 onto the acquisition system 300 may engage the container 45 and shake the container 45 rather than loading the container 45 onto the acquisition system 300.

[0172] The acquisition system 300 may shake the containers 45 by extending the carriage 460 into engagement with containers 45 identified as needing to be shaken. Carriage 460 then moves back while still engaging container 45 , pulling container 45 towards acquisition vehicle 310 . Carriage 460 again extends, pushing container 45 towards storage location 80 . As the carriage 460 retracts, it does not retract all the way to pull the container 45 onto the acquisition vehicle 310 . Specifically, the distance that the carriage 460 retracts is less than the length of the container 45 . In this manner, when the container 45 is shaken, the container 45 is not pulled completely out of the storage location 80 . Additionally, if storage location 80 includes a holder 84 that holds container 45, container 45 will remain in the open position while container 45 is being shaken.

[0173] As described above, the container 45 may be shaken by displacing the carriage 460 back and forth. Preferably, to arrange the contents within the container 45, the carriage 460 retracts and extends repeatedly to move the container 45 back and forth repeatedly. Additionally, during the shaking process, the carriage 460 may be driven forward at a faster rate than the carriage 460 moves backward. In this manner, items within the container 45 tend to be swung toward the front of the container 45, providing more space at the rear of the container 45 to receive the items. <How it works>

[0174] A system configured as described above is operable to automatically retrieve items from a number of receptacles. The method may optionally include automatically sorting the items into the bins. Sorting the items may involve any of a variety of methods. For example, the sorting step may include sorting a plurality of items into a sorting storage rack of bins in a plurality of storage locations. The containers may be arranged in multiple rows or columns.

[0175] The sorting step may optionally include the step of sequentially feeding the plurality of items into a plurality of transport vehicles. The transport vehicle can transport items to the receptacles for stacking the items in different receptacles. For example, each container may be associated with a particular order, so that a vehicle may deliver items to the container until all items for the order associated with the container have been delivered. Once a container has received all of the items intended for it, the container is identified as being full. Alternatively, a container may be identified as being full when enough items have been delivered to the container to fill it. Thus, a container identified as being full does not mean that the entire volume of the container is filled with items. Rather, a container may be identified as being full when all of its items (eg, all items in an order) have been delivered to the container. Additionally, the items in an order do not necessarily represent an individual customer order. An order may refer to any grouping of items identified by the control system. For example, a central warehouse may supply items to multiple retail stores. Here, an order refers to an area or aisle within each store, and items may be sorted into orders by area or aisle. Thus, an order may represent a group of items to be sent to a particular aisle in a particular store. Also, a particular order may require more than one container, such that multiple separate containers may be associated with a single order. Thus, the term order is meant to include any grouping of one or more items associated with a particular container or set of containers.

[0176] Thus, the method may include identifying that a container or set of containers for an order is full. Once a container is identified as full, it is automatically picked up and removed from the sorting area. For example, removing the full container may include obtaining the full container from a container sorting storage rack and transporting the full container away from the sorting storage rack. Additionally, the method may include placing the empty container in a storage location within the sortation storage rack from which the full container was obtained.

[0177] The method may include controlling the sorting process to prevent items from being delivered to a storage location having a fully loaded bin. Additionally, the method may optionally include controlling the sorting process to prevent items from being sorted into the storage location when the container is retrieved from the storage location. Additionally, the method may optionally include the step of resuming sorting of items to the empty storage location after the empty container has been transported to the empty storage location.

[0178] Additionally, the method of sorting may optionally include continuing to transfer items to less-full bins during the step of removing full bins.

[0179] The step of removing the full container may include moving an acquisition device to position the acquisition device adjacent to the full container. Optionally, moving the acquisition device may include raising a vertical track and moving the raised track.

[0180] The optional step of raising the vertical track may include raising the vertical track with an acquisition vehicle configured to travel along the floor. Moving the acquisition device may include driving the acquisition vehicle along the ground surface.

[0181] The step of removing the full container may include driving the acquisition vehicle vertically and driving a transfer mechanism that engages the full container and transfers the full container from the storage location onto the storage vehicle.

[0182] Optionally, driving the transfer mechanism includes connecting the acquisition vehicle to a displaceable carriage configured to engage the fully loaded container. Once the displaceable carriage is connected to the acquisition vehicle, a drive element on the acquisition vehicle may be actuated to extend the carriage away from the acquisition vehicle into engagement with the fully loaded container. Driving the transfer mechanism may include reversing a drive element of the acquisition vehicle to reverse the carriage with the fully loaded container towards the transport vehicle.

[0183] After the step of removing the loaded container, the method includes the step of displacing the loaded container away from the storage location from which it was removed. Displacing the fully loaded container may include driving the acquisition vehicle downwardly and then driving the acquisition vehicle along a path, such as a floor, to another area. For example, the step of moving the loaded containers may include moving the loaded containers to an output conveyor configured to receive the containers and transport the containers to a separate area for processing the loaded containers. Optionally, moving the fully loaded container includes raising the vertical track to move the vertical track with the fully loaded container. Alternatively, moving the fully loaded container may include moving the acquisition vehicle away from the vertical track.

[0184] Optionally, obtaining the full container may include engaging a container holder configured to hold the full container in a storage location. Additionally, the method may include displacing the retainer to open the container, and displacing the container from the storage location while displacing the retainer.

[0185] Optionally, the method may include acquiring a plurality of full containers and storing the acquired containers in an acquisition system. Acquiring the plurality of containers may include acquiring a first container, displacing the first container upwardly to a storage location of the acquisition system, and retaining the first container at the storage location of the acquisition system. While the first container is held in a storage location of the acquisition system, the acquisition system may acquire a full load of a second container and transfer the full load of the second container onto the acquisition system.

[0186] After obtaining the full second container, the method may include moving both the full first and second containers away from the sorting system simultaneously.

[0187] Where the method includes acquiring a plurality of fully loaded containers and storing the acquired containers in an acquisition system, the method may include determining an order for acquiring the plurality of containers. Determining the order may include identifying the highest container in the sorting storage rack and prioritizing that container as the first container to be picked up. Determining the order may include identifying a fully loaded second container located below the first container. Determining the order may include identifying a full third container that is located below a full second container.

[0188] The method may also include selectively placing the empty containers in a storage location. In particular, the method may include identifying empty storage locations. The acquisition system may be loaded with one or more empty containers. For example, the acquisition system may acquire and store one or more empty containers on the acquisition system.

[0189] The acquisition system may be transported to a location adjacent to a storage location that has been identified as empty. Specifically, the acquisition system may receive a signal from a central controller identifying a route to a storage location that has been identified as empty. When an acquisition system is positioned adjacent a storage location identified as empty, the acquisition system may transport an empty container to the storage location identified as empty.

[0190] Selectively placing the container in an empty storage location may include storing a plurality of empty containers on the acquisition system. Additionally, the method may include determining an order in which the empty storage locations receive the empty containers. Determining the order may include identifying a lowest located storage location within the sortation storage rack and prioritizing that storage location as the first storage location to receive empty containers from the acquisition system. Determining the order may include identifying a second empty storage location that is located above the first empty storage location. Determining the order may include identifying a third empty storage location that is located above the second empty storage location. The acquisition system may then transport the empty containers to the empty storage locations in the determined order.

[0191] As mentioned above, the acquisition system 300 may be integrated into the material handling system 10, which may be part of the overall automated warehouse system 5. The central controller may be part of a warehouse management system that includes software for tracking items, determining which items are needed for which orders, and managing which orders are processed by which material handling systems 10.

[0192] As mentioned above, a container may be identified as full when the material handling system 10 determines that all items for an order have been sorted into the container. Additionally, a container may be identified as being full if it is filled enough that there is no room to receive the item. The material handling system 10 may have one or more sensors to determine if a container is full when it cannot receive another item. For example, sortation system 50 may include multiple transport vehicles, as described above. The delivery vehicle may include a sensor that senses whether an item has been transferred from the delivery vehicle to the receptacle. If the container is fully loaded, the items within the container will block the transfer of items from the transport vehicle. Thus, the transport vehicle attempts to transfer the item, but the sensor indicates that the item is still on the transport vehicle due to an obstruction. Thus, if a delivery vehicle attempts to deliver an item but is unable to transfer the item to a receptacle, the system 10 may declare that the receptacle is full and needs to be picked up. The delivery vehicle then receives the signal and delivers the item to another location.

[0193] In some cases, items within a bin may prevent additional items from being sorted into the bin, even though there is sufficient space within the bin to receive the additional items. In particular, the items for an order may come in a variety of shapes and sizes. As various items are transported into the container, the items may be stacked irregularly such that there is a large amount of empty space underneath the items. In many cases, this problem can be solved by shaking the container to organize the items inside the container and take up less space. Thus, the material handling system 10 may include a method for selectively shaking the container to arrange the items within the container.

[0194] A method for selectively shaking a container includes distributing a plurality of items into the container. The method may also include identifying that the container needs to be shaken. The identifying step may include detecting if the item cannot be transferred to the container.

[0195] A method of shaking a container includes moving a transport mechanism into engagement with a container identified as needing to be shaken. The transfer mechanism then moves into engagement with the identified container. The transfer mechanism may then shake the container by moving it away from the storage location and then back towards the storage location. The steps of moving the container away from the storage location and then back towards the storage location may be repeated any number of times. After the step of shaking the container, the transfer mechanism may disengage from the container and move away from the container.

[0196] After shaking the container, the method may include delivering one or more additional items to the container.

[0197] As mentioned above, the process of identifying that the container needs to be shaken may include detecting and determining that an item cannot be transferred to the container. Alternatively, the step of determining whether the container needs to be shaken may be determined based on data relating to the volume of items delivered to the container. As mentioned above, the central controller may provide the sortation system with a list of items in the order. The central controller may contain data for each item being sorted, including volume information for each item. Thus, the central controller may track each item delivered to the container, allowing the central controller to track the total volume of all items delivered to the container. Thus, the system can determine that the container needs to be shaken if the total volume of items delivered to the container exceeds a threshold value.

[0198] Additionally, the process of identifying that a container needs to be shaken may include combining an analysis of the volume of items being delivered to the container with another signal indicating that the container is full and cannot receive the items. For example, as described above, if a transport vehicle attempts to transport an item to a bin but is unable to transfer the item into the bin, the failure to unload the item may be due to a jam or obstruction by an item within the bin. Specifically, if a transport vehicle attempts to transport an item but sensors on the transport vehicle indicate that the item remains on the transport vehicle, the transport vehicle sends a signal to the central controller indicating that the item was not transported. The central controller can then determine whether the volume of the items already delivered to the container exceeds a predetermined limit, such as a percentage of the container's volume. If the volume exceeds the limit, the central controller may determine that the container is full and send a signal that the container needs to be acquired. In response, the acquisition system 300 may be controlled to acquire the fully loaded container. Alternatively, if the central controller determines that the volume of items in the container is below a threshold, the central controller may identify that the container needs to be shaken. The central controller may then send a signal to the acquisition system indicating that the container needs to be shaken.

[0199] Optionally, if a container is identified as needing to be shaken, a delivery vehicle attempting to deliver an item to that container may remain at the storage location where the container is located. After the container is shaken, the delivery vehicle may attempt to deliver the items to the container. If the delivery vehicle is unable to deliver the item, the system may declare a jam. Alternatively, the transport vehicle may be driven from the bin to a discharge bin and discharge the items into the discharge bin.

[0200] In addition to the process of automatically identifying and shaking containers, it should be appreciated that a variety of criteria can be used to identify containers that need to be shaken. For example, in some circumstances, a sortation system may close after hours without completing all orders and retrieving all the containers containing items. Before resuming the sorting process, the central controller may identify all bins containing items and shake such bins to prepare the items. Similarly, the system may identify containers that have a certain volume of items and identify such containers as needing to be shaken before the sorting process can be resumed.

[0201] It should be appreciated that the method of shaking the container may be performed separately from the process of sorting items and obtaining a full container described above. Alternatively, the process of shaking the container may be incorporated into the process of sorting items into the containers and retrieving the full containers once they are full.

[0202] The order of the methods described herein may be changed, and various elements may be added, rearranged, combined, omitted, etc. All examples described herein are presented in a non-limiting manner. As will be apparent to those skilled in the art upon receipt of this disclosure, various modifications and variations are possible. Aspects of the present invention have been described with reference to specific embodiments. These embodiments are illustrative and not meant to be limiting. Many variations, modifications, additions, and improvements are possible. Thus, multiple elements may be provided for components described herein as a single element. Boundaries between various components, operations and data stores are somewhat arbitrary, and particular operations are illustrated in terms of specific illustrative configurations. Other allocations of functionality are contemplated and may fall within the scope of the claims below. Finally, structures and functionality presented as separate components in the exemplary configurations may be implemented as combined structures or components. These and other variations, modifications, additions and improvements may fall within the scope of the embodiments as defined in the claims that follow.

[0203] Thus, while the forgoing is directed to embodiments of the present invention, other and further embodiments may be devised without departing from the basic scope of the invention, which scope is determined by the appended claims.

Claims

1. a storage assembly having a plurality of elevated storage locations for storing items; a vehicle configured to transport items to and retrieve items from said storage location, said vehicle including first drive means, second drive means and transport means for driving said vehicle horizontally; a movable track having an opening configured to receive a portion of the vehicle and including means for engaging the second drive means of the vehicle; 1. A material handling system comprising: the means for engaging cooperates with the second drive means such that driving the second drive means in a first direction can lift the movable track off the ground and such that driving the second drive means in a second direction can drive the vehicle vertically upward to a raised position; the vehicle is configured to drive the vehicle along a horizontal plane to a location adjacent the storage assembly; A material handling system, wherein the transfer means is configured to transfer items between the vehicle and a storage location of the storage assembly while the vehicle is in the raised position adjacent the storage location.

2. the movable track includes a frame configured to receive the vehicle; The material handling system of claim 1 , wherein the vehicle is configured to pass through the opening into the frame.

3. 3. The material handling system of claim 2, wherein the second drive means and the movable track are configured for mating engagement such that entry of the vehicle into the frame causes the second drive means to operatively engage a vertical track of the movable track.

4. 4. A material handling system according to claim 1, wherein the movable track includes means for releasably connecting the movable track to the storage assembly.

5. 5. The material handling system of claim 4, wherein the releasably connecting means is configured to prevent displacement of the movable track relative to the storage assembly along at least one horizontal axis.

6. the means for releasably connecting includes a connector connected to the movable track; 6. A material handling system according to claim 4 or claim 5, wherein the connector is configured to connect the connector of the movable track to the storage assembly by relative vertical displacement between the movable track and the storage assembly.

7. The material handling system of claim 6 , wherein the connector is configured such that the movable track is decoupled from the storage assembly by vertical displacement of the connector relative to the storage assembly.

8. 8. A material handling system as claimed in any preceding claim, wherein the second drive means is configured to maintain an orientation of the vehicle relative to the horizontal as the vehicle is driven upwards.

9. the movable track includes a plurality of track segments extending vertically upward; the second drive system includes a plurality of interconnected second vertical drive means; 9. The material handling system of claim 8, wherein the plurality of vertical drive elements are synchronously driven upwardly along the plurality of track segments as the vehicle is driven upwardly to maintain a horizontal orientation of the vehicle.

10. 10. A material handling system as claimed in any one of claims 1 to 9, wherein the transport mechanism is connected to the first drive means such that driving the first drive system drives the transport mechanism from the vehicle towards the storage location.

11. 11. The material handling system of claim 10, further comprising a clutch for selectively engaging and disengaging said transport mechanism from said first drive means.

12. the storage location has a plurality of openings; the movable track includes an opening; 12. A material handling system as claimed in any one of claims 1 to 11, wherein an opening in the storage location is aligned with an opening in the movable track to provide a transfer opening through which the transfer mechanism is extendable.

13. 1. A material handling system operable with a storage assembly having a plurality of storage locations for storing a plurality of items, comprising: a vehicle for transporting items, the vehicle including: a horizontal drive assembly configured to drive the vehicle horizontally along a ground surface; a vertical drive assembly configured to drive the vehicle vertically upward; a transfer mechanism for transferring items between the vehicle and the storage location; and a power source for providing power to the horizontal drive assembly and the vertical drive assembly; 1. A material handling system comprising: a movable track including a vertical track cooperable with the vertical drive assembly of the vehicle; and a support structure configured to vertically support the vertical track, the movable track includes an opening configured to receive at least a portion of the vehicle; the vertical drive assembly and the vertical track are constructed and arranged such that when the vehicle is driven into the opening of the movable track, the vertical drive assembly engages the vertical track, such that driving the vertical drive assembly in a first direction can raise the movable track and driving the vertical drive assembly in a second direction can drive the vehicle upward along the track to a raised position to facilitate transfer of items between a storage location and the vehicle; The support structure is configured to support the vehicle when the vehicle is in the elevated position on the vertical track.

14. The material handling system of claim 13 , wherein the support structure includes a frame forming a row having an opening for receiving the vehicle.

15. 15. A material handling system according to claim 13 or claim 14, wherein the movable track includes a connector that releasably connects the movable track to the storage assembly.

16. The material handling system of claim 15 , wherein the connector is configured to prevent displacement of the movable track relative to the containment assembly along at least one horizontal axis.

17. 17. A material handling system according to claim 15 or claim 16, wherein the connector is configured to connect to the storage assembly by relative vertical displacement between the movable track and the storage assembly.

18. 20. The material handling system of claim 17, wherein the connector is configured such that the movable track is decoupled from the storage assembly by vertical displacement of the connector relative to the storage assembly.

19. 19. A material handling system as claimed in any one of claims 13 to 18, wherein the vertical drive assembly is configured to maintain an orientation of the vehicle relative to the horizontal as the vehicle is driven upwardly.

20. the vertical track includes a plurality of track segments extending vertically upward; the vertical drive assembly includes a plurality of vertical drive elements; 20. The material handling system of claim 19, wherein the plurality of vertical drive elements are interconnected to synchronously operate the vertical drive assemblies to drive the vehicle upwardly along the track segment while maintaining a horizontal orientation of the vehicle.

21. 21. A material handling system as claimed in any one of claims 13 to 20, wherein the transport mechanism is connected to one of the horizontal drive assembly and the vertical drive assembly such that driving one of the horizontal drive assembly and the vertical drive assembly drives the transport mechanism from the vehicle towards the storage location.

22. 22. The material handling system of claim 21 comprising a clutch for selectively engaging and disengaging the transport mechanism with the one of the horizontal drive assembly and the vertical drive assembly.

23. 23. A material handling system according to claim 21 or claim 22, wherein the transport mechanism is connected to the horizontal drive assembly.

24. 24. The material handling system of claim 13, wherein the vertical drive assembly protrudes outwardly from the vehicle and the support structure includes a gap configured to align with the vertical drive assembly to facilitate entry of the vehicle into the support structure.

25. 25. The material handling system of claim 24, wherein the vertical track assembly has an upper section and a lower section, each of the upper and lower sections including a plurality of teeth configured to cooperate with the vertical drive assembly, the upper and lower sections having a similar inter-tooth pitch, and the lower section having gaps between adjacent teeth to provide clearance to facilitate passage of the vertical drive through the lower section.

26. the vertical drive assembly includes a plurality of spur gears having a tooth pitch; 26. The material handling system of claim 25, wherein the spur gears are each rotatable about an axis, the axes of the plurality of spur gears are substantially parallel, and the spacing between the teeth of the lower section has sufficient clearance with respect to the teeth of the spur gears such that the teeth of the spur gears pass through the gaps as the spur gears move along a line parallel to their axis of rotation.

27. 27. The material handling system of claim 26, wherein the spur gear and the vertical track are constructed and arranged such that a tip circle of the spur gear overlaps a tip line of the teeth of the track.

28. the vertical track includes an upper section and a lower section; the upper section has an upper tooth shape having an upper root and an upper root; the lower section has a lower tooth profile having a lower root and a lower root greater than the upper root; 24. A material handling system as claimed in claim 23, wherein the lower roots of the teeth extend inwardly in a direction away from the vertical drive assembly further than the upper roots.

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