Autonomous transport vehicles

Abstract

This relates to conveying equipment for automated storage and retrieval systems. [Solution] The transport payload region further includes an articulated underpick end effector that engages with the payload against a payload support surface to underpick it, extends and retracts relative to the transport payload region to enable the movement of the payload. A payload alignment surface is mounted on the frame to engage with the payload. The payload alignment surface is positioned to provide at least two degrees of alignment in engagement with the payload to capture and fix the payload in a predetermined position within the transport payload region, and is configured to enable payload engagement by at least two degrees of alignment to align the payload to substantially coincide with the seating of the payload on the payload support surface of the transport payload region.

Description

Technical Field

[0001] Cross-Reference to Related Applications This application claims the benefit of and is a non-provisional application of U.S. Provisional Patent Application No. 63 / 236,591 filed on August 24, 2021, the entire disclosure of which is incorporated herein by reference.

[0002] The disclosed embodiments generally relate to material handling systems, and more specifically to conveying devices for automated storage and retrieval systems.

Background Art

[0003] Brief Description of Related Developments Generally, automated guided vehicles in logistics / warehouse facilities are manufactured to have a predetermined form factor for tasks assigned in a specific environment. These automated guided vehicles are configured with custom-cast or machined chassis / frames. Other components (e.g., wheels, transfer arms, etc.), some of which may be custom assemblies / components, are attached to the frame and carried together with the frame as the automated guided vehicle travels along a travel surface. The transfer arms and payload bays of these automated guided vehicles, in addition to transferring payloads to and from the automated guided vehicle, may include numerous components and motor assemblies for positioning the payload within the payload bay. The components of the transfer arms and payload bays and the numerous motors can be complex and lead to high manufacturing costs, which increases the cost and maintenance requirements of automated guided vehicles.

Summary of the Invention

[0004] The foregoing aspects and other features of the disclosed embodiments are described in the following description taken in conjunction with the accompanying drawings.

Brief Description of Drawings

[0005] [Figure 1]This is a block diagram of an exemplary automated storage and retrieval system incorporating aspects of the disclosed embodiments. [Figure 2A] Figure 1 is a schematic perspective view of an autonomous guided vehicle for an automated storage and retrieval system incorporating aspects of the disclosed embodiments. [Figure 2B] Figure 1 is a schematic perspective view of an autonomous guided vehicle for an automated storage and retrieval system incorporating aspects of the disclosed embodiments. [Figure 2C] Figure 1 is a schematic perspective view of an autonomous guided vehicle for an automated storage and retrieval system incorporating aspects of the disclosed embodiments. [Figure 2D] Figures 2A to 2C are schematic plan views of a portion of the autonomous guidance vehicle incorporating aspects of the disclosed embodiments. [Figure 2E] Figures 2A to 2D are illustrative schematic side views of some of the autonomous guided vehicles incorporating aspects of the disclosed embodiments. [Figure 2F] Figures 2A to 2D are illustrative perspective views of some of the autonomous guided vehicles incorporating aspects of the disclosed embodiments. [Figure 3A] These are schematic perspective views of parts of the autonomous guidance vehicle shown in Figures 2A to 2D according to the disclosed embodiments. [Figure 3B] This is a plan view of a portion of the autonomous guided vehicle shown in Figure 3A, according to an embodiment of the disclosed model. [Figure 4A] These are schematic perspective views of parts of the autonomous guidance vehicle shown in Figures 2A to 2D according to the disclosed embodiments. [Figure 4B] This is a plan view of a portion of the autonomous guided vehicle shown in Figure 4A, according to an embodiment of the disclosed model. [Figure 4C] This is a plan view of a portion of the autonomous guided vehicle shown in Figure 4A, according to an embodiment of the disclosed model. [Figure 5A] These are schematic perspective views of parts of the autonomous guidance vehicle shown in Figures 2A to 2D according to the disclosed embodiments. [Figure 5B] This is a plan view of a portion of the autonomous guided vehicle shown in Figure 5A, according to an embodiment of the disclosed model. [Figure 5C] This is a plan view of a portion of the autonomous guided vehicle shown in Figure 5A, according to an embodiment of the disclosed model. [Figure 6A] These are schematic perspective views of parts of the autonomous guidance vehicle shown in Figures 2A to 2D according to the disclosed embodiments. [Figure 6B] This is a plan view of a portion of the autonomous guidance vehicle shown in Figure 6A, according to an embodiment of the disclosed model. [Figure 6C] Figures 6A and 6B are plan views of a portion of the autonomous guided vehicle shown in the disclosed embodiment. [Figure 6D] Figure 6C is a plan view of a portion of the autonomous guided vehicle shown in the disclosed embodiment. [Figure 6E] This is a plan view of a portion of the autonomous guidance vehicle shown in Figure 6A, according to an embodiment of the disclosed model. [Figure 6F] Figures 6A and 6E are partial plan views of the autonomous guided vehicle shown in accordance with the disclosed embodiments. [Figure 6G] Figure 6F is a plan view of a portion of the autonomous guided vehicle shown in the disclosed embodiment. [Figure 7A] Figures 2A to 2D show schematic perspective views of a portion of the case handling assembly of an autonomous guided vehicle according to an embodiment of the disclosed model. [Figure 7B] Figures 2A to 2D show schematic perspective views of a portion of the case handling assembly of an autonomous guided vehicle according to an embodiment of the disclosed model. [Figure 8A] Figures 7A and 7B show schematic perspective views of the transport arm of the case handling assembly according to an embodiment of the disclosed features. [Figure 8B] Figures 7A and 7B show schematic perspective views of the transport arm of the case handling assembly according to an embodiment of the disclosed features. [Figure 8C] Figures 7A and 7B show schematic perspective views of the transport arm of the case handling assembly according to an embodiment of the disclosed features. [Figure 9A]It is a schematic perspective view of the transfer arm of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 9B] It is a schematic perspective view of the transfer arm of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 9C] It is a schematic perspective view of the transfer arm of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 10A] It is a schematic perspective view of the transfer arm of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 10B] It is a schematic perspective view of the transfer arm of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 10C] It is a schematic perspective view of the transfer arm of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 10D] It is a schematic perspective view of the transfer arm of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 11A] It is a schematic perspective view of a part of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 11B] It is a schematic perspective view of a part of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 11C] It is a schematic perspective view of a part of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 12A] It is a schematic perspective view of a part of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 12B] It is a schematic perspective view of a part of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 12C] It is a schematic perspective view of a part of the case handling assembly of FIGS. 7A and 7B according to an aspect of the disclosed embodiment. [Figure 12D] These are schematic perspective views of a portion of the case handling assembly shown in Figures 7A and 7B according to an embodiment of the disclosed features. [Figure 12E] These are schematic perspective views of a portion of the case handling assembly shown in Figures 7A and 7B according to an embodiment of the disclosed features. [Figure 12F] These are schematic perspective views of a portion of the case handling assembly shown in Figures 7A and 7B according to an embodiment of the disclosed features. [Figure 12G] These are schematic perspective views of a portion of the case handling assembly shown in Figures 7A and 7B according to an embodiment of the disclosed features. [Figure 12H] These are schematic perspective views of a portion of the case handling assembly shown in Figures 7A and 7B according to an embodiment of the disclosed features. [Figure 13A] These are schematic perspective views of a portion of the case handling assembly shown in Figures 7A and 7B according to an embodiment of the disclosed features. [Figure 13B] These are schematic perspective views of a portion of the case handling assembly shown in Figures 7A and 7B according to an embodiment of the disclosed features. [Figure 13C] These are schematic perspective views of a portion of the case handling assembly shown in Figures 7A and 7B according to an embodiment of the disclosed features. [Figure 13D] These are schematic perspective views of a portion of the case handling assembly shown in Figures 7A and 7B according to an embodiment of the disclosed features. [Figure 13E] These are schematic perspective views of a portion of the case handling assembly shown in Figures 7A and 7B according to an embodiment of the disclosed features. [Figure 13F] These are schematic perspective views of a portion of the case handling assembly shown in Figures 7A and 7B according to an embodiment of the disclosed features. [Figure 14A] Figures 2A to 2D are schematic perspective views of a portion of an autonomous guided vehicle, illustrating the sequence of picking and positioning an exemplary case unit according to an embodiment of the disclosed model. [Figure 14B]Figures 2A to 2D are schematic perspective views of a portion of an autonomous guided vehicle, illustrating the sequence of picking and positioning an exemplary case unit according to an embodiment of the disclosed model. [Figure 14C] Figures 2A to 2D are schematic perspective views of a portion of an autonomous guided vehicle, illustrating the sequence of picking and positioning an exemplary case unit according to an embodiment of the disclosed model. [Figure 14D] Figures 2A to 2D are schematic perspective views of a portion of an autonomous guided vehicle, illustrating the sequence of picking and positioning an exemplary case unit according to an embodiment of the disclosed model. [Figure 14E] Figures 2A to 2D are schematic perspective views of a portion of an autonomous guided vehicle, illustrating the sequence of picking and positioning an exemplary case unit according to an embodiment of the disclosed model. [Figure 14F] Figures 2A to 2D are schematic perspective views of a portion of an autonomous guided vehicle, illustrating the sequence of picking and positioning an exemplary case unit according to an embodiment of the disclosed model. [Figure 15] This is an exemplary flowchart for one or more exemplary methods according to aspects of the disclosed embodiments. [Figure 16] Figure 1 is an illustrative schematic diagram of a portion of the automated storage and retrieval system according to an embodiment of the disclosed features. [Figure 17A] Figures 2A to 2D show schematic cross-sectional views of the autonomous transport vehicle in the lowered position, according to an embodiment of the disclosed model. [Figure 17B] Figures 2A to 2D show schematic cross-sectional views of the autonomous transport vehicle in the lowered position, according to an embodiment of the disclosed model. [Figure 17C] Figures 2A to 2D show schematic cross-sectional views of the autonomous transport vehicle in the state where the payload platform is in the raised position, according to an embodiment of the disclosed model. [Figure 17D] Figures 2A to 2D show schematic cross-sectional views of the autonomous transport vehicle in the state where the payload platform is in the raised position, according to an embodiment of the disclosed model. [Figure 18]This is an exemplary flowchart for an exemplary method according to an embodiment of the disclosed embodiment. [Figure 19] This is an exemplary flowchart for an exemplary method according to an embodiment of the disclosed embodiment. [Modes for carrying out the invention]

[0006] Figure 1 illustrates an exemplary automated storage and retrieval system 100 according to an aspect of the disclosed embodiment. While aspects of the disclosed embodiment will be described with reference to the drawings, it should be understood that aspects of the disclosed embodiment can be embodied in many forms. Furthermore, elements or materials of any suitable size, shape, or type may be used.

[0007] As described in more detail herein, aspects of the disclosed embodiments provide an autonomous transport vehicle 110 of an automated storage and retrieval system 100 equipped with a multi-degree-of-freedom payload / case handling assembly. The payload handling assembly provides a simplified case handling structure compared to conventional warehouse autonomous transport vehicles, while securing the payload with six degrees of freedom while being held by the autonomous transport vehicle 110. The payload handling assembly reduces the number of parts and cost of the autonomous transport vehicle 110 by utilizing a general-purpose / common interchangeable structure (see, for example, lift towers 211, 122 described herein) that can be used at one or more locations on the autonomous transport vehicle 110. The payload handling assembly reduces the number of parts and cost of the autonomous transport vehicle 110 by minimizing the number of actuators / motors that enable the gripping and manipulation of the payload. Furthermore, as described herein, the payload handling assembly is configured to adapt to and stably hold payloads of various sizes by changing the distance between at least two adjacent payload support sections of the underpick end effector or arm 210A of the payload handling assembly, thereby reducing the number of parts and cost of the autonomous transport vehicle 110.

[0008] Aspects of the disclosed embodiments also provide the autonomous transport vehicle 110 with (a plurality of) alignment surfaces arranged to provide alignment of the payload in the payload area or bay of the autonomous transport vehicle 110 with at least two degrees of alignment to capture and secure the payload at a predetermined position within the payload area when engaged with the payload. As described herein, the alignment surfaces of the autonomous transport vehicle 110 are configured to provide engagement of the payload with at least two degrees of alignment to align the payload substantially simultaneously with the seating of the payload on the payload support surface of the payload area, so as to pick (and place) the payload and ensure that the payload is positioned within the payload area within about 10 seconds.

[0009] The automated storage and retrieval system 100 in Figure 1 may be located in a retail distribution center or warehouse to fulfill orders received from retailers for replenishment shipped in cases, packages, and / or parcels. The terms case, package, and parcel are used interchangeably herein and may be any container that may be used for shipping as described above and which may be filled by the manufacturer in cases or multiple product units. A case (one or more) as used herein means a unit of cases, packages, or parcels that are not stored (e.g., not contained) in a tray, on a tote, etc. It should be noted that a case unit CU (also referred to herein as a mixed case, case, and shipping unit) may include a case of goods / units (e.g., a case of soup cans, a box of cereal, etc.) or individual goods / units adapted to be removed from or placed on a pallet. According to exemplary embodiments, a shipping case or case unit (e.g., a carton, barrel, box, crate, jug, shrink-wrapped tray or group, or any other suitable device for holding a case unit) may have a variable size, be used to hold a case unit during shipping, and may be configured to be palletized for shipping. A case unit may also include totes, boxes, and / or containers of one or more individual goods (generally referred to as break-pack goods) that have been unpacked / released from their original packaging, and may be placed in a tote, box, and / or container (collectively referred to as a tote) together with one or more other individual goods of a mixed or common type at an order filling station. For example, it should be noted that when incoming bundles or pallets (e.g., from a manufacturer or supplier of case units) arrive at the automated storage and retrieval system 100 for replenishment, the contents of each pallet may be uniform (e.g., each pallet holds a predetermined number of the same items, i.e., one pallet holds soup and another pallet holds cereal).As can be understood, the cases in such a pallet load may be substantially similar, or in other words, homogeneous cases (e.g., similar dimensions) and may have the same SKU (otherwise, as previously stated, the pallet may be a “rainbow” pallet with layers formed of homogeneous cases). When the pallet leaves the automated storage and retrieval system, with the cases or totes filled with replenishment orders, the pallet may contain various case units in any appropriate number and combination (for example, each pallet may hold different types of case units, i.e., the pallet may hold combinations of canned soups, cereals, beverage packs, cosmetics, and household detergents). The cases assembled on a single pallet may have different dimensions and / or different SKUs.

[0010] The automated storage and retrieval system can generally be described as a storage and retrieval engine 190 coupled to a palletizer 162. More specifically here, and still referring to Figure 1, the automated storage and retrieval system 100 can be configured, for example, to be installed in an existing warehouse structure or adapted to a new warehouse structure. As previously mentioned, the system 100 shown in Figure 1 is representative and may include, for example, infeed and outfeed conveyors terminating at their respective transfer stations 170, 160, (one or more) lift modules 150A, 150B, storage structures 130, and a number of autonomous transport vehicles 110 (also referred to herein as “bots”). It should be noted that the storage and retrieval engine 190 is formed by at least the storage structure 130 and the bots 110 (and in some embodiments also by lift modules 150A, 150B, but in other embodiments the lift modules 150A, 150B may form a vertical sequencer in addition to the storage and retrieval engine 190, as described in U.S. Patent Application No. 17 / 091,265, filed November 6, 2020, titled “Pallet Building System with Flexible Sequencing,” the entire disclosure of which is incorporated herein by reference). In alternative embodiments, the automated storage and retrieval system may include a robot or bot transfer station (not shown) that can provide a connection between the bots 110 and (one or more) lift modules 150A, 150B. The storage structure 130 may include multiple (stacked) levels 130L1 to Ln of storage rack modules (see Figures 1 and 16, generally referred to as storage level 130 or storage level 130, where n is an integer indicating the upper number of storage levels present in the automated storage and retrieval system 100), where each level 130L includes its respective picking aisle 130A and a transport deck 130B for transporting case units between any of the storage areas of the storage structure 130 and the shelves of (one or more) lift modules 150A, 150B.In one embodiment, the picking passage 130A is configured to allow the bot 110 to move in an induced manner (such as along the rail 1600 (see Figure 16)), while in other embodiments, the picking passage is configured to allow the bot 110 to move in an unrestricted manner (for example, the picking passage is open and non-deterministic to the guidance / movement of the bot 110). The transport deck 130B has an open and non-deterministic bot-supporting moving surface along which the bot 110 moves under guidance and control provided by bot steering (as described herein). In one or more embodiments, the transport deck has multiple lanes between which the bot 110 moves freely to access the picking passage 130A and / or lift modules 150A, 150B. The picking passage 130A and the transport deck 130B also enable the bot 110 to place case units CU into the picking stock and retrieve the ordered case units CU. In an alternative embodiment, each level 130L may include its respective bot transfer station 140. The bot 110 may be configured to place case units, such as the retail goods described above, into a picking stock at one or more levels 130L of the storage structure 130, and then selectively retrieve the ordered case units to ship them, for example, to a store or other suitable location. Infeed transfer stations 170 and outfeed transfer stations 160 may work together with (one or more) their respective lift modules 150A, 150B to transfer case units CU bidirectionally to and from one or more levels 130L of the storage structure 130. The lift modules 150A, 150B may be described as dedicated inbound lift module 150A and outbound lift module 150B, but it should be noted that in an alternative embodiment, each of the lift modules 150A, 150B may be used for both inbound and outbound transfers of case units from the automated storage and retrieval system 100.While the embodiments of the disclosed models are described in relation to multi-level storage arrays, it should be noted that the embodiments of the disclosed models may also apply equally to single-level storage arrays located on or above the equipment floor.

[0011] To be understood, the automated storage and retrieval system 100 may include, for example, multiple infeed and outfeed lift modules 150A, 150B accessible by a bot 110 of the automated storage and retrieval system 100, so that one or more unaccommodated case units (e.g., one or more case units not held in a tray) or one or more accommodated case units (in a tray or tote) can be transported from lift modules 150A, 150B on each level 130L (see Figure 16) to each storage space 130S, and from each storage space on each level 130L to any one of the lift modules 150A, 150B. The bot 110 may be configured to transport case units between storage space 130S (e.g., located along picking aisle 130A or other suitable storage space / case unit buffer arranged along transport deck 130B) and lift modules 150A, 150B. Generally, the lift modules 150A, 150B include at least one movable payload support capable of moving (one or more) case units between infeed and outfeed transfer stations 160, 170 and each level 130L of the storage space 130S where (one or more) case units CU are stored and retrieved. The (one or more) lift modules may have any suitable configuration, such as a reciprocating lift, or any other suitable configuration. The (one or more) lift modules 150A, 150B may include any suitable controller (such as controller 120, or other suitable controllers connected to controller 120, warehouse management system 2500, and / or palletizer controllers 164, 164') and may form a sequencer or classifier in a manner similar to that described in U.S. Patent Application No. 16 / 444,592, filed June 18, 2019, titled "Vertical Sequencer for Product Order Fulfillment" (the entire disclosure of which is incorporated herein by reference).

[0012] The automated storage and retrieval system may include a control system comprising one or more control servers 120 that are communicably connected to infeed and outfeed conveyor and transfer stations 170, 160, lift modules 150A, 150B, and bots 110 via a suitable communication and control network 180. The communication and control network 180 may have any suitable architecture, which may incorporate various programmable logic controllers (PLCs) for, for example, commanding the automated operation of the infeed and outfeed conveyor and transfer stations 170, 160, lift modules 150A, 150B, and other suitable systems. The control servers 120 may include high-level programming to enable a case management system (CMS) 120 that manages the case flow system. The network 180 may further include suitable communication to enable a bidirectional interface with the bots 110. For example, the bots 110 may include an onboard processor / controller 1220. Network 180 may include a suitable bidirectional communication suite that enables bot controller 1220 to request or receive commands from control server 120 to enable desired transport of case units (e.g., placement to or retrieval from storage location) and to transmit desired bot 110 information and data, including bot 110 ephemeris, status, and other desired data, to control server 120. As seen in Figure 1, control server 120 may be further connected to a warehouse management system 2500 for providing inventory management and customer order fulfillment information to a CMS 120 level program, for example. A suitable example of an automated storage and retrieval system arranged for holding and storing case units is described in U.S. Patent No. 9,096,375, issued August 4, 2015, the entire disclosure of which is incorporated herein by reference.

[0013] Referring here to Figures 2A, 2B, 2C, and 2D, the autonomous transport vehicle or (also referred herein as an autonomous guided vehicle) bot 110 includes a frame 200F having a front end 200E1 and a rear end 200E2 that define the longitudinal axis LAX of the autonomous transport vehicle 110. The frame 200 may be constructed of any suitable material (e.g., steel, aluminum, composite material, etc.) and includes a case handling assembly 210 configured to handle cases / payloads transported by the autonomous transport vehicle 110. The frame 200F of the case handling assembly 210 forms a transport payload area (also referred to as a payload platform or payload area) 210B. As described herein, the payload platform 210B includes a payload contact support surface 610 (formed, for example, by a projection 620 of the position adjustment tray 600) that defines a payload support surface 610P (Figure 14E) of the vehicle 110 that supports a payload (for example, a case unit CU) held in the payload bay 210B as the vehicle passes through.

[0014] The autonomous transport vehicle also includes an optional suitable transport arm 210A (also called an articulated underpick end effector). The transport arm 210A is configured to engage with the payload, underpick the payload against the payload support surface 610P (Figure 14E), extend and retract against the payload bay 210B, and enable the transport of the payload to and from the payload bay 210B, thereby enabling unloading and loading from the payload bay 210B. Here, “underpick” is the picking of the payload by the end effector or transport arm 210A, where the transport arm 210A is positioned / configured to engage with the underside of the payload CU and pick up the payload CU from there (i.e., lift it from below) (for example, formed by the vertical array of storage racks VAS (see Figure 16)) and enable the transport of the payload CU from at least one of the transport racks (such as lift 150) of each predetermined storage area 130S of the storage rack and input / output stations 160, 170 to the vehicle 110. In a similar but opposite manner, the underpick end effector or transport arm 210A transports the payload CU on the payload platform 210B, and from there transports and decisively underpicks the payload / case unit CU (via bottom engagement) to position the payload CU in the storage space 130S of the storage rack / transport shelf (such as the vertical array of the storage shelf VAS or other suitable payload holding area of ​​the automated storage and retrieval system). During the pick / position / operation, the exchange in the underpick between the transport arm 210A and the storage rack support 900S of the storage space 130S (see, for example, Figure 9) allows for the selection of multiple case units on the storage rack (with a substantially free and unhindered tolerance).The case units on the storage rack engage with the underside / bottom of the payload / case unit CU, allowing for latitude, so that they can have tightly packed spacing between them (i.e., spacing along the length of the storage rack extending substantially parallel to the moving lane of the picking passage 130A or the transport deck 130B), and the tight spacing is independent of the lateral deformation of the cases. The transport arm 210A is configured to transport the payload between the autonomous transport vehicle 110 and the payload holding position (such as any suitable payload storage position, the shelves of the lift modules 150A, 150B, and / or any other suitable payload holding position). The transport arm 210A may be configured to extend laterally (LAT) and / or vertically (VER) to transport the payload to and from the case handling assembly 210. In embodiments illustrated in Figures 2A and 2B, the case handling assembly 210 includes at least one lift tower 211, 212 configured to move the transport arm 210A and / or payload platform 210B vertically VER, as will be described in more detail herein; however, in other embodiments, the case handling assembly 210 may not have at least one lift tower 211, 212. Examples of suitable payload platforms 210B and transfer arms 210A and / or autonomous transport vehicles to which aspects of the disclosed embodiments may be applied are, in whole, incorporated herein by reference, U.S. Patent Publication No. 2012 / 0189416, published July 26, 2012, entitled “Automated Bot with Transfer Arm” (U.S. Patent Application No. 13 / 326,952, filed December 15, 2011), and U.S. Patent No. 7,591630, issued September 22, 2009, entitled “Materials-Handling System Using Autonomous Transfer and Transport Vehicles.”U.S. Patent No. 7,991505, issued on August 2, 2011, titled "Vehicles"; U.S. Patent No. 9,561905, issued on February 7, 2017, titled "Autonomous Transport Vehicle"; U.S. Patent No. 9,082112, issued on July 14, 2015, titled "Autonomous Transport Vehicle Charging System"; U.S. Patent No. 9,850079, issued on December 26, 2017, titled "Storage and Retrieval System Transport Vehicle"; U.S. Patent No. 9,187244, issued on November 17, 2015, titled "Bot Payload Alignment and Sensing"; U.S. Patent No. 9,499338, issued on November 22, 2016, titled "Automated Bot Transfer Arm Drive System"; "Bot Having High Speed This can be seen in U.S. Patent No. 8,965,619, issued on February 24, 2015, titled "Stability"; U.S. Patent No. 9,008,884, issued on April 14, 2015, titled "Bot Position Sensing"; U.S. Patent No. 8,425,173, issued on April 23, 2013, titled "Autonomous Transports for Storage and Retrieval Systems"; and U.S. Patent No. 8,696,010, issued on April 15, 2014, titled "Suspension System for Autonomous Transports".

[0015] The frame 200 includes one or more suitable idler wheels 250 positioned adjacent to the front end 200E1. The idler wheels 250 may be substantially similar to those described in U.S. Provisional Patent Application No. 63 / 213,589, filed on 22 June 2021, titled "Autonomous Transport Vehicle with Suspension," with Patent Attorney No. 1127P015753-US(-#2), and in U.S. Provisional Patent Application No. 63 / 193,188, filed on 26 May 2021, titled "Autonomous Transport Vehicle with Steering," with Patent Attorney No. 1127P015753-US(-#5), which are incorporated herein by reference in their entirety. The frame also includes one or more drive wheels 260 positioned adjacent to the rear end 200E2. The drive wheel 260 may be substantially similar to that described in U.S. Provisional Patent Application No. 63 / 213,589, filed June 22, 2021, whose entire disclosure is incorporated herein by reference. In other embodiments, the positions of the idler wheel 250 and the drive wheel 260 may be reversed (for example, the drive wheel 260 is located at the front end 200E1 and the idler wheel 250 is located at the rear end 200E2).

[0016] It should be noted that in some embodiments, the autonomous transport vehicle 110 is configured to move with its front end 200E1 leading the direction of movement, or with its rear end 200E2 leading the direction of movement. For illustrative purposes only, idler wheels 250A, 250B (substantially similar to the idler wheel 250 described herein) are positioned at the respective front corners of the front end 200E1 of the frame 200, and drive wheels 260A, 260B (substantially similar to the drive wheel 260 described herein) are positioned at the respective back corners of the rear end 200E2 of the frame 200 (for example, support wheels are positioned at each of the four corners of the frame 200), thereby enabling the autonomous transport vehicle 110 to stably travel through the transport deck 130B and picking passage 130A of the storage structure 130. In other examples, idler wheels 250A and 250B are located at their respective back corners at the rear end 200E2 of the frame 200, and drive wheels 260A and 260B (which are substantially similar to the drive wheels 260 described herein) are located at their respective front corners at the front end 200E1 of the frame 200.

[0017] Each drive wheel 260 is equipped with a drive unit 261 that is independently connected to the frame 200 in any suitable way, such as by a suspension system 280, so that each drive wheel 260 is movable independently of the frame, and any other drive wheels 260 (one or more) are also connected to the frame in a manner substantially similar to that described in U.S. Provisional Patent Application No. 63 / 213,589, filed on 22 June 2021, entitled "Autonomous Transport Vehicle with Suspension," which is incorporated herein by reference in its entirety. It should be noted that each drive unit 261 is equipped with any suitable drive motor 261M and wheel 261W. The drive motor 261M is connected to the wheel 261W and rotates it to propel the autonomous transport vehicle 110 in the direction of movement. Here, the motors 261M of the two drive wheels 260A and 260B may be operated simultaneously at approximately the same rotational speed to propel the autonomous transport vehicle 110 along a substantially linear path of movement. In other embodiments, the motors 261M of the two drive wheels 260A and 260B may be operated simultaneously (or at different times) at different rotational speeds to propel the autonomous transport vehicle 110 along a curved path of movement, or to pivot the autonomous transport vehicle in direction 294 around a vehicle pivot axis 293. The vehicle pivot axis 293 may be located approximately midway between the two drive wheels 260A and 260B. The differential operation of the motors 261M of each drive wheel 260A and 260B that enables the turning and / or pivoting of the autonomous transport vehicle 110 as described above is referred to herein as differential drive wheel steering.

[0018] The case handling assembly 210 is described with reference to Figures 3A-5C, in addition to Figures 2A and 2B. As described above, the case handling assembly 210 includes a transport arm 210A and / or a payload platform (or bay) 210B. In this embodiment, the payload platform 210B is movably connected to at least one lift tower 211, 212 for vertical movement VER, and the transport arm 210A is movably connected to the payload platform 210B for lateral movement LAT. The payload platform 210B includes a payload platform frame 210BF which forms a payload area where case units carried by the bot 110 are arranged for transport throughout the automated storage and retrieval system 100. The payload platform frame 210BF includes longitudinal ends 210BE1, 210BE2, each connected to one of at least one lift tower 211, 212. Here, at least one lift tower includes a lift tower 211 positioned at or adjacent to the front end 200E1 of frame 200 and a lift tower 212 positioned at or adjacent to the rear end 200E2 of frame 200. Here, each lift tower 211, 212 includes a movable carriage or carrier 290 to which one of each of its longitudinal ends 210BE1, 210BE2 is fixed and connected by any suitable method such as mechanical or chemical fasteners (i.e., as the movable carrier 290 moves, the payload platform frame 210BF moves with the movable carrier 290).

[0019] Referring to Figures 3A and 3B, in one or more embodiments, as described above, the vehicle 110 includes at least one lift tower 211, 212. Each of the at least one lift tower 211, 212 is substantially similar to each of the at least one lift tower 211, 212, so as only lift tower 211 and its carrier 290 are described (i.e., lift towers 211, 212 are interchangeable / common with each other and may be positioned adjacent to either the front end 200E1 or the rear end 200E2 of frame 200). Lift tower 211 includes a tower frame 300F. The tower frame 300F includes a base 305, vertical guides 306, 307, and a cross brace or brace 308. The carrier or movable payload carriage 290 extends laterally between vertical guides 306, 307 and is guided by vertical movement by the vertical guides 306, 307 (for example, the carrier 290 is configured to raise and lower the payload CU within the payload area 210B). For example, the lift tower 211 includes vertical guides 306, 307, each of which forms guide rails 306R, 307R that guide the movement of the carrier 290. The joint between the guide rails 306R, 307R and the carrier 290 is nondeterministic with respect to the torsional position of the carrier 290 relative to the guide rails 306R, 307R. For example, the vertical guides 306, 307 may have "C"-shaped channels that form the guide rails 306R, 307R. Here, the vertical guides 306, 307 are simple and inexpensive extruded (or punched or near-net-shape cast) structures that reduce costs and facilitate the easy assembly / disassembly of the lift towers 211, 212 relative to the frame 200F. The carrier 290 includes ends 290E1, 290E2 that are received within their respective guide rails 306R, 307R.The ends 290E1 and 290E2 engage with the respective guide rails 306R and 307R and may include any suitable low-cost lubricating bushings 290B that can be easily inserted into (and removed from) the respective guide rails 306R and 307R to facilitate the easy assembly and disassembly of the carrier 290 relative to the guide rails 306R and 307R. The ends 290E1 and 290E2 and their respective lubricating bushings 290B engaged with the guide rails 306R and 307R are configured to restrict the movement of the carrier 290 in the longitudinal direction LON, while allowing the unrestricted movement of the carrier 290 in direction VER within the guide rails 306R and 307R (i.e., the lubricating bushings 290B have running fit clearance with the guide rails 306R and 307R so that the guide rails do not need to be manufactured with tight / small tolerances). Lubricating bushings 290B provide easily replaceable sacrificial material, which are connected to the respective ends 290E1, 290E2 by removable fasteners, snaps, clips, or any other suitable removable couplings. Guide rails 306R, 307R provide smooth / quick movement of the carrier 290 in direction VER as the carrier 290 is raised / lowered relative to the frame 200F, and hereby, torsional rigidity of the carrier 290 is provided by flexible transmission units 330 that facilitate non-deterministic joint connections between the ends 290E1, 290E2 and the guide rails 306R, 307R, as described herein.

[0020] A drive section 390S having at least one degree of freedom of motion is connected to the carrier 290 by a flexible transmission 330. Here, the flexible transmission movably connects the carrier 290 to at least one lift tower 211, 212, and the drive section 290S is configured to move the carrier 290 relative to at least one lift tower 211, 212. For example, the carrier 290 moves vertically VER between the base 305 and the brace 308 under the power of any suitable drive motor 390 of the drive section 390S, where, for example, the drive motor 390 is connected to the carrier 290 by a flexible transmission 330 (such as one described herein). In one embodiment, the drive motor 390 is a rotary motor connected to the carrier 290 via a flexible transmission 330 (e.g., a belt, chain, and / or cable), while in other embodiments, the drive motor 390 may be a linear motor (e.g., any suitable electric, hydraulic, and / or pneumatic linear actuator) connected to the carrier 290 to move the carrier 290 in direction VER. In the embodiment illustrated in Figure 3A, the frame includes pulleys 320-325 (or sprockets in embodiments where a chain is used) rotatably connected thereto. Pulleys 320, 321 are connected to the base 305, while pulleys 322-325 are connected to the brace 308. A meandering flexible transmission member 330 extends around the pulleys 320-325 and is connected to the carrier 290. In the illustrated embodiment, the meandering flexible transmission member 330 is a toothed belt and the pulley is a toothed pulley; however, as described above, in other embodiments, the meandering flexible transmission member 330 is any suitable cable, chain, or other transmission member capable of meandering routing.

[0021] The flexible transmission unit 330 is configured to enable torsional stability of the carrier 290 and the payload CU held thereon (note that the carrier 290 carries the payload platform 210B and the transport arm 210A as described herein) relative to the frame 200F and independently of each other joint between the carrier 290 and the at least one lift tower 211, 212, rather than the flexible transmission unit 330 connecting the carrier 290 to at least one lift tower 211, 212. For example, as described above, the joints between the ends 290E1, 290E2 and the guide rails 306R, 307R are non-deterministic so that a running clearance is provided between them, allowing the ends 290E1, 290E2 to move freely in direction VER. The configuration of the flexible transmission unit 330 described herein restricts the ends 290E1, 290E2 to at least direction VER so as to provide torsional stability of the carrier 290. As can be understood, the flexible transmission unit 330 is configured to drive the carrier 290 in direction VER along the vertical guides 306, 307, providing torsional stability of the carrier 290 over the entire range of operation of the carrier 290 relative to at least one lift tower 211, 212. The flexible transmission unit 330 is also configured to provide torsional stability of the carrier 290 over the entire range of operation of the carrier 290 relative to at least one lift tower 211, 212, providing payload transfer from the carrier 290 (e.g., payload platform 210B and the transport arm 210A carried by it) to payload support shelves (such as in a vertical array of storage shelves VAS or any other payload holding area of ​​an automated storage and retrieval system), as described herein.Similarly, the flexible transmission unit 330 is configured to provide torsional stability of the carrier 290 over the entire range of motion of the carrier 290 with respect to at least one lift tower 211, 212, which brings about payload transfer from a payload support rack (such as in a vertical array of storage racks VAS or any other payload holding area of ​​an automated storage and retrieval system) to the carrier 290 (e.g., a payload platform 210B and the transfer arm 210A carried by it).

[0022] For example, the flexible transmission member 330 is endless or otherwise forms a closed-loop transmission where the ends of the flexible transmission member 330 are fixed to each other or adjacent to each other. The closed-loop transmission is configured to provide torsional stability to the carrier 290 such that the carrier 290, the payload platform 210B, and the transport arm 210A, which is connected to and carried by the payload platform 210B, remain in a predetermined spatial orientation with respect to one or more of the frame 200F, the moving surface on which the autonomous guided vehicle 110 moves, and the case seating surface to which the case unit is transported (for example, such that the transport arm 210A and the payload platform 210B are substantially parallel to the case unit CU holding position in order to allow the transport arm 210A to pick up and position the case unit CU). For example, extension of the transport arm 210A for picking or placing a case unit causes the center of mass of the transport arm 210A (and any case unit or object carried on the transport arm 210A) to move laterally (LAT) relative to the frame 200F (and the carrier 290 of at least one lift tower 211, 212). This lateral movement of the center of mass of the transport arm 210A (and any object carried on it) induces a torsional moment at least on the carrier 290, which is resisted / countered by a closed-loop transmission formed by a flexible transmission member (belt, chain, cable, etc.) 330.

[0023] An exemplary meandering (closed-loop) transmission path of the flexible transmission member 330 is illustrated in Figure 3B, where the flexible transmission member 330 is fixedly connected to the carrier 290 at couplings 340, 341 adjacent to the side ends of the carrier 290 (so that when the flexible transmission member 330 moves, the carrier moves with the flexible transmission member 330). As can be understood, the further apart the couplings 340, 341 are, the greater the resistance of the carrier 290 to torsional loads created, for example, by the extension of the transfer arm 210A. As described above, the drive motor 390 drives the movement of the flexible transmission member 330 (and the carrier 290 connected thereto).

[0024] In the embodiment illustrated in Figure 3A, the drive motor 390 is attached to the tower frame 300F in any suitable way, such as using mechanical or chemical fasteners. Pulleys 320 and 321 connected to the base 305 are connected to the base 305 such that the axle PXL of each pulley 320 and 321 is accessible via the side of the base 305 for connection using a drive coupling DC or driven pulley 350. Here, the driven pulley 350 (or sprocket) is connected to the axle PCL of pulley 320 (or pulley 321), where the driven pulley 350 is connected to the drive pulley 351 (or sprocket) of the motor 390 by a drive belt 352 or a chain or cable. In other embodiments, the drive shaft of the motor 390 may be connected substantially directly to the axle PXL of pulley 320 (or pulley 321). The axle PXL of pulley 320 is also connected to the drive shaft 355 by a drive coupling DC, where one end of the drive shaft 355 is connected to the axle PXL of pulley 320 of the lift tower by a drive coupling DC, and the other end of the drive shaft 355 is connected to the axle PXL of pulley 320 of the lift tower by another drive coupling DC, so that the respective flexible transmission members 330 of the lift towers 211 and 212 are driven by a common motor (i.e., motor 390 drives the flexible transmission members 330 of both lift towers 211 and 212), and so that the carriers 290 (of the lift towers 211 and 212) connected to the respective flexible transmission members 330 are moved in sync with direction VER. Here, the axle PXLs of pulleys 320, 321 are configured to engage with the driven pulley 350 and the corresponding recess of the drive coupling DC in any suitable manner, such as by forming a spline coupling, a hexagonal drive coupling, or any other suitable drive coupling, so that the driving force is transmitted to the axle PXL of each pulley 320, 321. In another embodiment, each lift tower 211, 212 has its own motor for driving the movement of its respective belt (and the carrier connected thereto) (where the motors are synchronized in any suitable manner, such as by using a suitable encoder).

[0025] Referring to Figures 4A, 4B, and 4C, in one or more embodiments, the lift towers 211, 212 are substantially similar to those described above with respect to Figures 3A and 3B, except that the carriers 290 of each lift tower 211, 212 are driven by a flexible transmission member 430 (substantially similar to the flexible transmission member 330 described above) and stabilized against torsional forces by separate and different flexible stabilizing members 435, 436 (belts, chains, cables, etc.) from the flexible transmission member 430. In this embodiment, pulley 421 is connected to the base 305 in a manner substantially similar to the pulleys 320, 321 described above, and pulley 422 is connected to the brace 308 in a manner substantially similar to the pulleys 322-325 described above. The flexible transmission member 430 forms a continuous / endless loop around the pulleys 421, 422. In one or more embodiments, the flexible transmission member 430 is a toothed belt and the pulleys 421, 422 are toothed pulleys, but in other embodiments, any suitable belt, chain, cable, etc., as well as pulleys may be used. The carrier 290 is connected to one side of the continuous loop by a coupling 340, as illustrated in Figure 4C, in order to drive the carrier 290 in direction VER when the flexible transmission member 430 is driven around the pulley by the motor 390, in a manner substantially similar to that described above with respect to the flexible transmission member 330 (in this embodiment, the motor 390 is exemplified as being connected substantially directly to the axle PXL of the pulley 421 by any suitable drive coupling similar to that described above, where the pulleys 421 of the lift towers 211 and 212 are connected by a drive shaft 355 in a manner substantially similar to that described above, so that the flexible transmission member 430 and the carrier 290 of the lift towers 211 and 212 move synchronously in direction VER). In other embodiments, each lift tower 211, 212 may have its own drive motor 390 for driving its respective flexible transmission member 430, where the rotation of the drive motors is synchronized in any suitable way (such as the method described herein).

[0026] As described above, the carriers 290 of each lift tower 211, 212 illustrated in Figures 4A to 4C are stabilized against torsion (for example, against torsional forces induced by the extension of the transfer arm 210A) by a pair of flexible stabilizing members 435, 436 positioned adjacent to or on the side ends of each carrier 290. Each flexible stabilizing member 435, 436 has ends 435E1, 436E1 fixed and connected to the brace 308 (by any suitable method such as mechanical or chemical fasteners) and other ends 435E2, 436E2 fixed and connected to the base 305 (by any suitable method such as mechanical or chemical fasteners). Each flexible stabilizing member 435, 436 follows a meandering path (shown in Figure 4B) between the brace 308 and the base 305, where the meandering path is defined at least partially by a pair of offset pulleys 423A, 424A and 423B, 423B (or sprockets if a chain is used) which are rotatably connected adjacent to or at the side ends of the carrier 290 (as illustrated in Figure 4A). Here, pulleys 423A, 424A are offset in both the vertical VER and the longitudinal LON. Pulleys 423B, 424B are also offset in both the vertical VER and the longitudinal LON, so that, as illustrated in Figure 4B, pulleys 423A, 423B are substantially aligned with each other in the LAT direction (i.e., coaxial with each other), and pulleys 424A, 424B are substantially aligned with each other in the LAT direction (i.e., coaxial with each other). As shown in Figures 4A and 4B, the flexible stabilizing member 435 forms a meandering path around pulleys 423A and 424A, and the flexible stabilizing member 436 forms a meandering path around pulleys 423B and 424B. The meandering paths of each flexible stabilizing member 435 and 436 form a substantial S-shape around their respective pulleys 423A, 424A, 423B, and 424B.Pulley 424A is rotatably fixed to pulley 424B by shaft 450 (or any other suitable mechanical connection) in conjunction with the meandering paths of flexible stabilizing members 435, 436 to maintain the relative position of the carrier 290 with at least the frame 300F in order to prevent the carrier 290 from tilting or inclining under torsional loads induced on the carrier 290 by the extension of the transport arm 210A as described herein (i.e., when pulley 424A rotates, pulley 424B also rotates with pulley 424A). In other embodiments, pulleys 423A, 423B are also rotatably fixed to each other in a manner similar to that described above with respect to pulleys 424A, 424B. In other embodiments, instead of rotatably fixing pulleys 424A, 424B, pulleys 423A, 423B are rotatably fixed to each other.

[0027] Referring to Figures 5A, 5B, and 5C, in one or more embodiments, the lift towers 211, 212 are substantially similar to those described above with respect to Figures 4A, 4B, and 4C, except that the carrier 290 of each lift tower 211, 212 differs from the flexible transmission member 430 in that it is stabilized against torsional forces by opposing flexible stabilizing members 535, 536 (exemplified as cables, but in other embodiments, chains, belts, etc.) that extend at least in the LAT direction along the carrier 290. For example, the carrier 290 of each lift tower 211, 212 includes pulleys 590, 591 positioned on one side of the carrier 290 and pulleys 592, 593 positioned on the other side of the carrier 290 such that the respective rotation axes SPX1, SPX2 of the pulleys extend in the LON direction and the pulleys are positioned substantially parallel to the plane of each lift tower 211, 212. In other embodiments, pulleys 590-593 are located on the same / common side of the carrier 290. Pulleys 591, 593 located at or adjacent to one end of the carrier 290 are arranged coaxially along the axis SPX2, and pulleys located at or adjacent to the other end of the carrier 290 are arranged coaxially along the axis SPX1, however, in other embodiments, pulley 591 does not have to be coaxial with pulley 593, and pulley 590 does not have to be coaxial with pulley 592.

[0028] The flexible stabilizing member 535 is wrapped around pulleys 590, 591 along a meandering path (a substantially "S" shaped path as illustrated in Figure 5B) such that one end 535E1 of the flexible stabilizing member 535, located at or adjacent to the end 290E1 of the carrier 290 and extending from pulley 591, is fixedly connected to brace 308, and the other end 535E2 of the flexible stabilizing member 535, located at or adjacent to the other end 290E2 of the carrier 290 and extending from pulley 590, is fixedly connected to base 305. The flexible stabilizing member 535 is wrapped around pulleys 592, 593 in a manner opposite to the flexible stabilizing member 535. For example, the flexible stabilizing member 536 is wrapped around the pulleys 590, 591 along a meandering path (a substantially "S" shaped path as illustrated in Figure 5C) such that one end 536E1 of the flexible stabilizing member 536, located at or adjacent to the end 290E1 of the carrier 290 and extending from the pulley 593, is fixedly connected to the base 305 (for example, the end 536E1 of the flexible stabilizing member 536 faces the end 535E1 of the flexible stabilizing member 535), and the other end 536E2 of the flexible stabilizing member 536, located at or adjacent to the other end 290E2 of the carrier 290 and extending from the pulley 592, is fixedly connected to the brace 308 (for example, the end 536E2 of the flexible stabilizing member 536 faces the end 535E2 of the flexible stabilizing member 535). The arrangement of these opposing, serpentine, flexible stabilizing members, as illustrated in Figures 5A, 5B, and 5C, maintains the relative position of the carrier 290 with at least the frame 300F in order to prevent the carrier 290 from tilting or inclining under torsional loads induced on the carrier 290 by the extension of the transport arm 210A as described herein.

[0029] Referring again to Figures 2A and 2B, as well as Figures 6A, 6B, 6C, 6D, 6E, 6F, and 6G, as described above, the payload platform frame 210BF is connected to the lift towers 211 and 212 (for example, via the carrier 290) and extends between the lift towers 211 and 212. In other embodiments, the payload platform frame 210BF is cantilevered from one lift tower or connected to two or more lift towers. A position adjustment tray 600 is mounted on the payload platform frame 210BF. The position adjustment tray 600 includes a base 630 and at least one case unit support surface 610 connected to (or integrally formed with) the base 630 in any suitable manner. At least one case unit support surface 610 forms a case unit support surface 610P, along which a case unit CU carried by the bot 110 can be moved laterally and / or longitudinally to reposition / relocate the case unit CU on the payload table 210B, as described herein. In one or more embodiments, the at least one case unit support surface 610 is one or more projections 620 extending from the base 630, where each projection 620 has an arc-shaped surface 621 on which the case unit is supported. In another embodiment, the at least one case unit support surface 610 is one or more laterally extending rollers 620A extending in direction LAT, while in yet another embodiment, the at least one case unit support surface 610 is formed by a plurality of ball bearings 620B forming a ball transfer table, while in yet another embodiment, the at least one case unit support surface 610 may be formed by a combination of projections, rollers, and ball bearings.

[0030] Referring to Figures 6A and 6E-6G, the base 630 of the position adjustment tray 600 is connected to the payload base frame 210BF in any suitable manner such that when the payload base frame 210BF moves in the VERT direction relative to the frame 200F of the bot 110, the position adjustment tray 600 moves with the payload base frame 210BF. For example, the payload base frame 210BF includes a guide member 666P (e.g., a post, rod, etc.) that captures and holds the position adjustment tray to the payload base frame 210BF, along which the position adjustment tray slides in the VERT direction. In one or more embodiments, any suitable biasing member 666 (e.g., a spring, elastic / rubber bush, etc.) is provided to bias the position adjustment tray 600 away from the payload base frame 210BF (in the VERL direction), but in other embodiments, gravity and / or the biasing member 666 may bias the position adjustment tray 600 in the VERL direction. When the position adjustment tray 600 is biased to move away from the payload base frame 210BF (see Figure 6E), the case unit support surface 210AFS of the tine or finger 210AF of the transfer arm 210A (as described herein) is positioned above the payload support surface 610P of the position adjustment tray 600. When the position adjustment tray 600 moves toward the payload base frame 210BF (for example, against the biasing force of one or more biasing members 666, such as contact between the position adjustment tray 600 and the frame 200F, and / or against gravity), the case unit support surface 210AFS of the tine or finger 210AF of the transfer arm 210A is positioned below the payload support surface 610P so that the case unit CU is transferred from the case unit support surface 210AFS of the finger 210AF to one or more support surfaces 610 of the position adjustment tray 600 (see Figures 6F and 6G).

[0031] As illustrated in Figures 6A and 6F, at least a portion of the payload platform frame 210BF and at least a portion of the base 630 of the positioning tray 600 are shaped and sized to fit into and recess within the frame 200F of the bot 110. The position adjustment tray 600 is configured such that when a portion of the payload platform frame 210BF is lowered / retracted in direction VERL into the opening 670 of the frame 200F (for example, by the lift towers 211, 212), the projection 620 abuts against the frame 200F (or any other suitable rigid stop surface of the bot 110), seating the position adjustment tray 600 on the frame 200F (or any other suitable tab or portion of the base 630 in the case of rollers 620A and ball bearings 620B), and the projection 620 (or any suitable tab or portion of the base 630 in the case of rollers 620A and ball bearings 620B) extends onto the frame 200F to move toward the payload platform frame 210BF (in the embodiment illustrated in Figure 6A, the projection extends in the lateral direction LAT, but in other embodiments, any suitable tab may extend in the longitudinal direction LON and / or lateral direction LAT). As the payload platform frame 210BF continues to move in direction VERL (and the frame 200F stops the movement of the repositioning tray 600 in direction VERL), the payload support surface 610P is positioned above the tine or the case unit support surface 210AFS of the finger 210AF to transfer the case unit CU from the finger 210AF to the repositioning tray 600 (for example, the support portion of the case unit is transferred from the transfer arm 210A to the repositioning tray 600 for repositioning / relocation in direction LON, LAT). Any suitable elastic material (e.g., rubber (or other elastomer / elastic material) bushings, pads, etc.) may be placed between the repositioning tray 600 and the frame 200F to substantially dampen vibrations in and out of the frame 200F.

[0032] As the case unit is repositioned / relocated, the lift towers 211, 212 move the payload platform 210B in the direction VERU so that the biasing member 666 and / or gravity bias the repositioning tray 600 away from the payload platform frame 210BF (for example, in the direction VERL). The continued movement of the payload platform 210B in the direction VERU causes the case unit support surface 210AFS of the finger 210AF to move across (for example, onto) the payload support surface 610P of the repositioning tray 600 to transfer the support portion of the case unit CU from the repositioning tray 600 to the finger 210AF. As can be understood, the case unit CU can be transported by the bot 110 while supported on the repositioning tray and / or on the finger 210AF. The position adjustment tray 600 is also configured to hold any debris (e.g., liquid and / or solid) from the case unit CU held / supported within the payload platform 210B by the transfer arm 210A or the position adjustment tray 600, such as within the trough 665 (see Figures 6B and 7B) adjacent to / between the case unit support surface 610. The holding of case unit debris by the position adjustment tray 600 can prevent the debris from falling onto, for example, the transfer deck 130B (Figure 1) and the picking passage 130A (Figure 1), where such fallen debris could reduce wheel traction between the wheels of the bot 110 and the moving / supporting surfaces of the transfer deck 130B and the picking passage 130A.

[0033] Referring to Figures 6A and 6B-6D, in one or more alternative embodiments, the base 630 of the position adjustment tray 600 is connected to the payload base frame 210BF in any suitable way (using a guide member 666P, for example) such that the position adjustment tray 600 moves with the payload base frame 210BF when the payload base frame 210BF moves in the VERT direction relative to the frame 200F of the bot 110. In one or more embodiments, the position adjustment tray 600 is connected to the payload base frame 210BF by a biased coupling that provides relative movement of the position adjustment tray 600 relative to the payload base frame 210BF in the VERT direction, while biasing the position adjustment tray 600 against the payload base frame 210BF in the VERT direction. For example, one or more suitable biasing members 666 (e.g., springs, elastic / rubber bushings, etc.) bias the position adjustment tray 600 toward the payload base frame 210BF in direction VERL (see Figure 6A), resulting in relative movement between the position adjustment tray 600 and the payload base frame in direction VERT. When the position adjustment tray 600 is biased against the payload base frame 210BF (see Figure 6B), the case unit support surface 210AFS of the tine or finger 210AF of the transfer arm 210A (as described herein) is positioned over the payload support surface 610P of the position adjustment tray 600. When the position adjustment tray 600 is moved away from the payload base frame 210BF (for example, against the biasing force of one or more biasing members 666 due to contact, etc.), the case unit support surface 210AFS of the tine or finger 210AF of the transfer arm 210A is positioned below the payload support surface 610P so that the case unit CU is transferred from the case unit support surface 210AFS of the finger 210AF to one or more support surfaces 610 of the position adjustment tray 600 (see Figures 6C and 6D).

[0034] As illustrated in Figures 6A and 6D, at least a portion of the payload platform frame 210BF and at least a portion of the base 630 of the position adjustment tray 600 are shaped and sized to fit into and recess within the frame 200F of the bot 110. When a portion of the payload platform frame 210BF is lowered / retracted into the opening 670 of the frame 200F (for example by the lift towers 211, 212) in direction VERL, the projection 620 of the position adjustment tray 600 abuts against the frame 200F (or any other suitable rigid stop surface of the bot 110), seating the position adjustment tray 600 on the frame 200F (or any other suitable rigid stop surface of the bot 110) and moving away from the payload platform frame 210BF (for example, in direction VERL). The position adjustment tray 600 is stopped by the frame 200F, but the payload platform frame 210BF continues to move in direction VERL. The projection 620 (or, in the case of rollers 620A and ball bearings 620B, any suitable tab or portion of the base 630) is configured to extend onto the frame 200F (in the embodiment illustrated in Figure 6A, the projection extends in the lateral direction LAT, but in other embodiments, any suitable tab may extend in the longitudinal direction LON and / or lateral direction LAT). As the payload platform frame 210BF continues to move in direction VERL, the case unit support surface 210AFS of the finger 210AF moves past (below) the payload support surface 610P of the positioning tray 600 to transfer the case unit CU from the finger 210AF to the positioning tray 600 (for example, the support portion of the case unit is transferred from the transfer arm 210A to the positioning tray 600 for positioning / repositioning in directions LON, LAT).

[0035] As the case unit is repositioned / relocated, the lift towers 211, 212 move the payload platform 210B in the direction VERU so that the biasing member 666 biases the repositioning tray 600 against the payload platform frame 210BF (for example, in the direction VERL). The continued movement of the payload platform 210B in the direction VERU causes the case unit support surface 210AFS of the finger 210AF to move across (for example, onto) the payload support surface 610P of the repositioning tray 600 to transfer the support portion of the case unit CU from the repositioning tray 600 to the finger 210AF. As can be understood, the case unit CU can be transported by the bot 110 while supported on the repositioning tray and / or on the finger 210AF. The position adjustment tray 600 is also configured to hold any debris (e.g., liquid and / or solid) from the case unit CU held / supported within the payload platform 210B by the transfer arm 210A or the position adjustment tray 600, such as within the trough 665 (see Figures 6B and 7B) adjacent to / between the case unit support surface 610. The holding of case unit debris by the position adjustment tray 600 can prevent the debris from falling onto, for example, the transfer deck 130B (Figure 1) and the picking passage 130A (Figure 1), where such fallen debris could reduce wheel traction between the wheels of the bot 110 and the moving / supporting surfaces of the transfer deck 130B and the picking passage 130A.

[0036] The position adjustment tray 600 is positioned relative to the fingers 210AF of the transfer arm 210A such that the case unit support surface 210AFS of the fingers 210AF is positioned at a predetermined distance (e.g., a gap) CAG above the support surface 610 of the position adjustment tray 600, with the payload platform 210B raised relative to the frame 200F for picking and / or positioning the case unit CU. This gap CAG is sized (i.e., minimized) only to allow sufficient clearance between the case unit CUs supported on the fingers 210AF so that the movement of the case unit CUs on the support surface 610 (e.g., the arched support surface 621) is non-contact between the case unit CUs and the support surface 610. As described herein, the minimized gap CAG, through relative vertical movement between the finger 210AF and the positioning tray 600 (for example, the relative movement of the positioning tray 600 is brought about by the frame 200F or actuator 666A), positions the underpicked case unit CU within the payload bay 210B and results in the case unit CU being seated on the positioning tray 600 substantially very close to the end effector 210A that will be loaded into the payload bay 210B. For example, once the retraction movement of the transfer arm 210A into the payload platform 210B is complete, the case unit CU is transferred to the positioning tray 600 substantially simultaneously with, and substantially immediately after the completion of the retraction movement, by relative movement between the transfer arm 210A and the positioning tray 600. The support surface 610 has a coefficient of friction sufficient to stably hold the case unit CU on it so that it is aligned with a 2-degree alignment (vertical in direction VER and plane in direction LON, LAT), enabling the commencement of the passage operation of the autonomous transport vehicle 110 substantially simultaneously with the completion of the retraction movement (for example, the case unit is retracted into the payload platform 210B and securely aligned on the position adjustment tray 600, and the passage of the vehicle 110 begins within approximately 10 seconds) (when the case unit is not gripped by the position adjustment bars 222, 223, pusher arm 1150, or case puller).As described herein, the position adjustment tray 600 extends over the fingers via contact with the frame 200F, while the payload bay 210B may include a linear actuator 666A (see Figures 6B and 6E) for raising or lowering the position adjustment tray 600 relative to the fingers 210A. For example, the linear actuator 666A may be used when the transport arm 210A and payload platform 210B are raised (e.g., via lift towers 211, 212) to pick a case unit CU from the upper shelf 900U of an array of stacked shelves (see Figure 16).

[0037] Referring to Figures 2A, 2B, 7A, and 7B, as described above, the transport arm 210A is movably connected to the payload platform frame 210BF in any suitable way such that the fingers 210AF of the transport arm 210A are separated from the payload platform frame 210BF by any suitable distance 667 in direction VER (Figure 2B). For example, the transport arm 210A includes an extension shaft 270 connected to the payload platform frame 210BF and configured to cause movement of the fingers 210AF relative to the payload platform frame 210BF in direction LAT. Here, the extension shaft 270 includes a linear guide rail 271 connected to the payload platform frame 210BF at or adjacent to end 210BE1 of the payload platform frame 210BF, and another linear guide rail 272 connected to the payload platform frame 210BF at or adjacent to end 210BE2 of the payload platform frame 210BF. The finger 210AF is connected to the finger support rail 273 of the transfer arm 210A, where the finger support rail 273 straddles and is movably connected to the linear guide rails 271 and 272 for reciprocating motion (e.g., extension and retraction) along the linear guide rails 271 and 272 in the direction LAT. The transfer arm 210A includes any suitable motor 275 (e.g., rotary motor, linear motor, etc.) and transmission unit 276 (e.g., belt, gear, etc.) for driving the finger support rail 273 along the linear guide rails 271 and 272, enabling the reciprocating motion of the finger 210AF to the direction LAT. In the embodiment illustrated in the drawings, the transport arm 210A extends and retracts from one side of the frame 200F of the bot 110, but in other embodiments, the transport arm 210A is configured for bidirectional extension (for example, extending and retracting from both sides of the frame 200F of the bot 110).

[0038] In the embodiments illustrated in Figures 2A, 2B, 7A, and 7B, there are three fingers 210AF1, 210AF2, and 210AF3 connected to the finger support rail 273 (see Figures 7A and 7B), but in other embodiments, there are more or fewer than three fingers connected to the finger support rail 273. Here, one or more of the fingers 210AF1, 210AF2, and 210AF3 are movably connected to the finger support rail 273 so as to be movable along the finger support rail 273 in direction LON to at least change / alter the pitch or distance between the fingers 210AF1, 210AF2, and 210AF3. In one or more embodiments, one or more of what are called the outer fingers 210AF1, 210AF3 are movable relative to one or more of what are called the inner fingers 210AF2. For example, finger 210AF2 may be stationary and fixed in a predetermined position on a finger support rail, such as on or along the laterally extending centerline 777 of the payload platform 210B (e.g., not moving relative to finger support rail 273), or finger 210AF2 may be driven in direction LON independently of one or more of the outer fingers 210AF1, 210AF3.

[0039] At least fingers 210AF1, 210AF3 are connected to the finger support rail 273 so as to move toward each other and toward finger 210AF2 in direction LON, but in other embodiments, each of fingers 210AF1, 210AF2, and 210AF3 is connected to the finger support rail 273 so as to move toward each other. The finger support rail 273 includes any suitable number of linear actuators 776 for bringing the movement of fingers 210AF1, 210AF3 or fingers 210AF1, 210AF2, and 210AF3 toward direction LON. Fingers 210AF1, 210AF2, and 210AF3 may be movable toward direction LON independently of each other, either in a fixed relationship with one or more other fingers or as a single unit. The linear actuator is any suitable actuator, which may include, but is not limited to, a pneumatic cylinder, a hydraulic cylinder, a ball screw drive, a feed screw drive, a rack and pinion drive, a rotary arm linkage drive, a belt drive, a chain drive, or any other suitable drive configured to bring about the linear movement of a finger along a finger support rail to a directional LON.

[0040] In one or more embodiments, each finger 210AF1, 210AF3 has its own linear actuator 776 such that the fingers 210AF1, 210AF3 move independently of each other in direction LON, while in other embodiments, there is a single linear actuator 776 common to each finger 210AF1, 210AF3 such that a single actuator 776 moves each of the fingers 210AF1, 210AF3 in direction LON in a fixed relationship. As an example, the linear actuator 776 is common to both fingers 210AF1, 210AF3 and includes a lead screw 776S having a stepper motor 776M (or other suitable motor), a right-hand lead screw portion 776R, and a left-hand lead screw portion 776L, where the lead screw 776S is connected to the stepper motor. One of the fingers 210AF1, 210AF3 is connected to the right-hand lead screw portion 776R, and the other of the fingers 210AF1, AF3 is connected to the left-hand lead screw portion 776L, so that when the stepper motor rotates both the left-hand and right-hand lead screw portions 776L, 776R simultaneously in a first rotational direction, the fingers 210AF1, 210AF2 move away from each other and away from finger 210AF2, increasing the distance between the fingers 760A, 760B to any appropriate increasing distance 760A', 760B', 760A'', 760B''. When the stepper motor 776M rotates both the left-hand and right-hand lead screw portions 776L and 776R simultaneously in a second rotational direction (opposite to the first rotational direction), the fingers 210AF1 and 210AF2 move toward each other and toward finger 210AF2, reducing the distance between the fingers 760A', 760B' to the distance 760A, 760B, or reducing the distance between the fingers 760A'', 760B'' to the distance 760A', 760B' or 760A, 460B, or any other suitable distance.Distances 460A, 760B, 760A', 760B', 760A'', and 760B'' correspond to the size of the case unit being picked / transported (case units having lengths / widths of 6 inches, 14 inches, and 24 inches are exemplified, but in other embodiments, the case unit may have any suitable length / width (see Figures 8A-8C)), the spacing between the protrusions 620 of the position adjustment tray 600 (Figures 7A and 7B), and / or the spacing between the slats 900S of the case unit support 900 in the case unit holding position (Figure 9A). As described above, when a single actuator drives the motion of fingers 210AF1 and 210AF3, distance 760A' is approximately the same as distance 760B', and distance 760A'' is approximately the same as distance 760B''. However, when each finger 210AF1 and 210AF3 is driven by its own respective actuator, distance 760A' may be different from distance 760B', and distance 760A'' may be different from distance 760B''. In some embodiments, finger 210AF2 may also be driven along finger support rail 273 in direction LON.

[0041] As can be understood, any suitable guide rail / slide 850 (Figures 8A, 8B) is included with the linear actuator 776, along which fingers 210AF1, 210AF3 move, using finger 210AF2, to be maintained in a predetermined orientation relative to the payload base 210B and finger 210AF2, defining the case unit support surface CUSP. The case unit support surface CUSP is substantially parallel / coplanar with the case unit support surface CUSPH defined by the case unit support portion 900 in the case unit holding position (Figure 9A).

[0042] In one or more embodiments, the actuator 776 and the fingers 210AF2 are coupled to a carriage 773 such that the actuator 776 (and the fingers 210AF1, 210AF3 coupled thereto) and the fingers 210AF2 move in direction LON along one or more rails 774 under the thrust of the actuator 775 (for example, the actuator moves the fingers 210AF1, 210AF2, 210AF3 and the actuator 776 in direction LON). The actuator 775 may be substantially similar to the actuator 776 described herein. Here, the fingers 210AF1, 210AF2, 210AF3 move as a unit in direction LON so as to be positioned beneath the payload CU (to underpick it) and to transport the payload CU, which has been positioned in direction LON (by position adjustment bars 222, 223, etc., as described herein), to somewhere within the payload platform 210B. The carriage 773 is sized to allow longitudinal movement of the fingers as described herein, and so that the fingers can be positioned anywhere within the payload platform 210B in direction LON and positioned relative to each other to pick up any appropriately sized payload CU. In one or more embodiments, the carriage 773 may be a telescopic carriage having telescopic sections 773TS that extend and retract to provide the range of motion of the outer fingers 210AF1, 210AF3 as described herein, while allowing the fingers 210AF1, 210AF2, 210AF3 to move together in direction LON as a single unit. In one embodiment, the telescopic section 773TS of the carriage 773 may be extended and retracted in a manner substantially similar to the finger method illustrated in and described with respect to Figures 9A-10D, but in other embodiments, the telescopic section 773TS may be extended and retracted in any suitable manner to provide the range of motion (as described herein) of the outer finger of the transport arm 210A.By moving fingers 210AF1, 210AF2, and 210AF3 together as a unit in direction LON (together with carriage 773, etc.), or by moving each finger 210AF1, 210AF2, and 210AF3 independently in direction LON, a position-adjusted pick / position of the payload CU in the manner described herein (e.g., center position adjustment or off-center position adjustment), where the payload CU is position-adjusted by position adjustment bars 222 and 223.

[0043] In Figures 7A and 7B, each finger 210AF1, 210AF2, and 210AF3 includes a product support portion 710 and a connecting portion 711 that connects the product support portion to the finger support rail 273. In Figures 7A and 7B, the connecting portions 711 of fingers 210AF1, 210AF2, and 210AF3 are substantially parallel to each other, but in other embodiments, the connecting portions 711 of one or more fingers 210AF1, 210AF2, and 210AF3 are angled relative to another connecting portion of fingers 210AF1, 210AF2, and 210AF3, as shown in Figures 8A to 8C. In the example shown in Figures 8A to 8C, the connecting portions 711G1 and 711F3 of fingers 210AF1 and 210AF3 are angled toward each other and toward the connecting portion 711F2 of finger 210AF2. This coupling configuration reduces the distance between couplings in the connection between fingers 210AF1, 210AF2, 210AF3 and finger support rail 273, thereby providing a more compact linear actuator 776 and reducing the weight / cost associated with such a linear actuator 776. Movement of one or more of fingers 210AF1, 210AF2, 210AF3 in direction LON also substantially prevents interference between fingers 210AF1, 210AF2, 210AF3 and case unit CU held in adjacent positions (e.g., adjacent case units) at a given case unit holding position where the case unit is positioned / picked by bot 110.

[0044] Referring to Figures 9A-9C, in one or more embodiments, the transfer arm 210A includes reconfigurable finger segments 210S1-210S7, each substantially similar to the fingers 210AF described herein, unless otherwise specified. The finger segments 210S1-210S7 are reconfigurable via the operation of a linear actuator to change / reconfigure the number of fingers 210AF1-210AF7 that the transfer arm 210A has. For example, in embodiments illustrated in Figures 9A-9C, the finger segments 210S1-210S3 and 210S5-210S7 are movable in direction LON in a manner similar to that described above to increase or decrease the number of fingers. In Figure 9A, the transfer arm 210A is illustrated as having three fingers 210AF1-210AF3. Here, finger segments 210S1 to 210S7 are arranged in a segment group to form finger 210AF1 (formed by finger segments 210S1 and 210S2), finger 210AF2 (formed by finger segments 210S3, 210S4 and 210S5), and finger 210AF3 (formed by finger segments 210S6 and 210S7). In Figure 9B, the transfer arm 210A is illustrated as having five fingers 210AF1 to 210AF5, where finger segments 210S1 to 210S7 are arranged in a segment group to form finger 210AF1 (formed by finger segment 210S1), finger 210AF2 (formed by finger segment 210S2), finger 210AF3 (formed by finger segments 210S3, 210S4, and 210S5), finger 210AF4 (formed by finger segment 210S6), and finger 210AF5 (formed by finger segment 210S7).In Figure 9C, the transfer arm 210A is shown having seven fingers 210AF1 to 210AF7 (however, in other embodiments, there may be more or fewer fingers), where the finger segments 210S1 to 210S7 are arranged such that each finger segment 210S1 to 210S7 forms its own finger 210AF1 to 210AF7.

[0045] In a manner similar to that described above, the finger segment 210S4 is fixed in place on the finger support rail 273, such as on or along the laterally extending centerline 777 of the payload platform 210B (for example, not moving relative to the finger support rail 273). The other finger segments 210S1-210S3, 210S5-210S7 are movable along the finger support rail 273 in direction LON so as to position the fingers 210AF1-210AF3 in Figure 9A, the fingers 210AF1-210AF5 in Figure 9B, and the fingers 210AF1-210AF7 in Figure 9C at distances 760A, 760B, 760A', 460B', 760A'', and 760B'' respectively relative to the stationary finger segment 210S4. In other embodiments, however, the distance between adjacent finger segments may be any appropriate distance that positions the finger segments in the space between the slats 900S of the case unit support portion 900 in the case unit holding position.

[0046] The movement of finger segments 210A1 to 210S7 is brought about in a manner similar to that described above with respect to Figures 7A to 8C, where finger segments 210S1 and 210S7 are connected, for example, to one of the left and right lead screws 776L and 776R, respectively. The movement of finger segments 210S2 and 210S3 in direction LON is subordinate to the movement of finger segment 210S1, and the movement of finger segments 210S5 and 210S6 in direction LON is subordinate to the movement of finger segment 210S7. For example, finger segments 210S2 and 210S3 are connected to each other via a rigid link 920 such that the distance between finger segments 210S2 and 210S3 in direction LON is fixed (for example, does not change). A slotted link 921 is connected to finger segment 210S2, where the slotted link 921 includes a slot 921S through which at least a portion of finger segment 210S1 reciprocates in direction LON. Finger segments 210S5 and 210S6 are connected to each other via a rigid link 922 such that the distance between finger segments 210S2 and 210S3 in direction LON is fixed (e.g., does not change). A slotted link 923 is connected to finger segment 210S6, where the slotted link 923 includes a slot 923S through which at least a portion of finger segment 210S7 reciprocates in direction LON. Although links 920 and 921 are described as separate links, in other embodiments, links 920 and 921 may be formed as a single one-piece link that connects finger segments 210S2 and 210S3 by setting the distance between them, forming a slot 921S through which finger segment 210S1 reciprocates. Similarly, although links 922 and 923 are described as separate links, in other embodiments, links 922 and 923 may be formed as a single one-piece link that connects finger segments 210S5 and 210S6 by setting the distance between them, forming a slot 923S through which finger segment 210S7 reciprocates.As described above, any appropriate number of dependent fingers may be included in the transfer arm 210A, and more than seven fingers may be provided so that they can operate in an extension and retraction manner substantially similar to the extension and retraction method described herein.

[0047] Referring to Figures 9A to 9C in order, Figure 9A illustrates the contracted configuration of finger segments 210S1 to 210S7, where finger segment 210S1 substantially abuts against finger segment 210S2, finger segments 210S3 and 210S5 substantially abut against finger segment 210S4, and finger segment 210S7 substantially abuts against finger segment 210S6. The linear actuator 776 is operated to move finger segment 210S7 toward the end 210BE2 of the payload platform 210B (see Figure 7A) in direction LON, and finger segment 210S1 toward the end 210BE1 of the payload platform 210B in direction LON. As shown in Figure 9B, the finger segment 210S1 moves along the slot 921S until it reaches a distance of 760A', so that as the finger segment 210S1 moves toward the end 210BE1, the finger segments 210S1 and 210S2 are separated and reconfigured as fingers 210AF1 and 210AF2. One or more of the rigid link 920, finger segment 210S2, and finger segment 210S3 are held in place by any suitable stopper (e.g., biased ball and recess) or any suitable biasing member (e.g., spring) during the movement of finger 210S1 to a distance of 760A'. As finger segment 210S7 moves toward end 210BE2, finger segment 210S7 moves along slot 923S until it reaches distance 760B', so that finger segments 210S6 and 210S7 are separated and reconfigured as fingers 210AF4 and 210AF5. One or more of the rigid link 922, finger segments 210S5, and finger segments 210S6 are held in place by any suitable stopper (e.g., biased ball and recess) or any suitable biasing member (e.g., spring) during the movement of finger 210S7 to distance 760B'. It should be noted that finger segments 210S3-210S5 are reconfigured as finger 210AF3.

[0048] As shown in Figure 9C, further movement of finger 210S1 toward end 210BE1 in direction LON causes finger 210S1 to engage with end 921SE of slot 921S. As finger segment 210S1 continues to move toward end 210BE1 while engaged with end 921SE, finger segment 210S1 pulls finger segments 210S2 and 210S3 toward end 210BE1 by links 921 and 920 (for example, the movement of finger segments 210S2 and 210S3 is subordinate to the movement of finger segment 210S1). Here, finger segments 210S1 to 210S3 are reconfigured as fingers 210AF1 to 210AF3, respectively, and positioned at distances 760'', 760A', and 760A. Similarly, further movement of finger segment 210S7 toward end 210BE2 in direction LON causes finger 210S7 to engage with end 923SE of slot 923S. As finger segment 210S7 continues to move toward end 210BE2 while engaged with end 923SE, finger segment 210S7 becomes a link 922 and 923 pull finger segments 210S5 and 210S6 toward end 210BE2 (for example, the movement of finger segments 210S5 and 210S6 is subordinate to the movement of finger segment 210S1). Here, finger segments 210S1 to 210S3 are reconfigured as fingers 210AF5 to 210AF7, respectively, and positioned at distances 760B, 760B'', and 760B''. It should be noted that finger segment 210S4 is reconfigured as finger 210AF4.As can be understood, the reconfiguration of the finger segments from fingers 210AF1-210AF7 to fingers 210AF1-210AF5 and from 210AF1-210AF5 to 210AF1-210AF3 is carried out in substantially the reverse manner of the above, where the retraction movement of finger segments 210S1 and 210S7 causes finger segment 210S1 to substantially contact finger segment 210S2, pushing finger segments 210S2 and 210S3 toward finger segment 210S4, and finger segment 210S7 to substantially contact finger segment 210AS6, pushing finger segments 210S5 and 210S6 toward finger segment 210S4.

[0049] Referring to Figures 10A to 10D in order, Figure 10A illustrates finger segments 210S1 to 210S7 in a contracted configuration substantially similar to that of Figure 9A, where finger segment 210S1 substantially abuts against finger segment 210S2, finger segments 210S3 and 210S5 substantially abut against finger segment 210S4, and finger segment 210S7 substantially abuts against finger segment 210S6. However, in the configuration illustrated in Figures 10A to 10C, the respective connections between finger segment 210S1 and finger segment 210S2, and between finger segment 210S6 and finger segment 210S7, are articulated link connectors 1010A and 1010B. For example, finger segment 210S1 is connected to rail 273R of finger support rail 273 by slide 1021. Finger segments 210S2 and 210S3 are connected to rail 273R by slide 1020 so as to be spaced a predetermined distance apart from each other in a manner substantially similar to that described with respect to Figures 9A to 9C. Finger segment 210S7 is connected to rail 273R of finger support rail 273 by slide 1023. Finger segments 210S5 and 210S6 are connected to rail 273R by slide 1022 so as to be spaced a predetermined distance apart from each other in a manner substantially similar to that described with respect to Figures 9A to 9C. The articulated link connector 1010A includes a first link 1011 and a second link 1012. The first link 1011 is pivotably connected to slide 1020 at its proximal end around axis 1010X1 (see Figure 10D for articulated link connector 1010B, which is substantially similar to articulated link connector 1010A). The proximal end of the second link 1012 is pivotably connected to the distal end of the first link 1011 by axis 1010X. The distal end of the second link 1012 is pivotably connected to slide 1021 around axis 1010X2 (see Figure 10D for slide 1023). Axis 1010X is guided by guide channel 1010C to fold in the opposite direction to slides 1020 and 1021.For example, the shaft 1010X includes a post or pin 1099 (see Figure 10D) that extends into and follows the guide channel 1010C such that when folded, the guidance of the shaft 1010X along the guide channel 1010C substantially prevents the coupling / locking of the first link 1011 and the second link 1012, and positions the shaft 1010X such that the first link 1011 and the second link 1012 are in a spatial relationship opposite to the finger segments 210S1 and 210S2.

[0050] Similarly, the articulated linkage 1010B includes a first link 1011 and a second link 1012. The first link 1011 is pivotably connected to the slide 1022 at its proximal end, around axis 1010X1. The proximal end of the second link 1012 is pivotably connected to the distal end of the first link 1011 at axis 1010X. The distal end of the second link 1012 is pivotably connected to the slide 1023 around axis 1010X2. Axis 1010X is guided by the guide channel 1010C to fold in the opposite direction to slides 1020 and 1021. For example, the shaft 1010X includes a post or pin 1099 (Figure 10D) that extends into and follows the guide channel 1010C such that when folded, the guidance of the shaft 1010X along the guide channel 1010C substantially prevents the coupling / locking of the first link 1011 and the second link 1012, and that positions the shaft 1010X such that the first link 1011 and the second link 1012 are in a spatial relationship opposite to the finger segments 210S6 and 210S7.

[0051] In a manner similar to that described above, finger segments 210A1 and 210S7 are driven simultaneously in opposite directions along the finger support rail 273 in direction LON so that they move toward and away from each other. For example, a linear actuator 776 can be operated to move finger segment 210S7 toward end 210BE2 of the payload platform 210B (see Figure 7A) in direction LON, and finger segment 210S1 toward end 210BE1 of the payload platform 210B in direction LON. As shown in Figure 10B, the movement of finger segment 210S1 (and the slide 1021 to which finger segment 210S1 is connected) toward end 210BE1 causes finger segment 210S1 to move along rail 273 until it reaches a distance of 760A', so that finger segments 210S1 and 210S2 are separated and reconfigured as fingers 210AF1 and 210AF2 (for example, by unfolding the first link 1011 and the second link 1012 of the articulated link connector 1010A relative to each other). One or more of the slide 1020 to which finger segments 210S2 and 210S3 are connected, finger segment 210S2, and finger segment 210S3 are held in place by any suitable stoppers (for example, biased balls and recesses) during the movement from finger segment 210S1 to a distance of 760A'. As the finger segment 210S7 (and the slide 1023 to which it is connected) moves toward end 210BE2, the finger segment 210S7 moves along the rail 273 until it reaches a distance of 760B', so that the finger segments 210S6 and 210S7 are separated and reconfigured as fingers 210AF4 and 210AF5 (for example, by unfolding the first link 1011 and the second link 1012 of the articulated link connector 1010A relative to each other).Slide 1022, to which finger segments 210S5 and 210S6 are connected, and one or more of finger segments 210S5 and 210S6 are held in place by any suitable stopper (e.g., a biased ball and recess) during movement from finger 210S7 to a distance of 760B'. It should be noted that finger segments 210S3 to 210S5 are reconfigured as finger 210AF3.

[0052] As shown in Figure 10C, further movement of finger 210S1 toward end 210BE1 in direction LON causes finger 210S1 / slide 1021 to pull slide 1020 (and the finger segments 210S2, 210S3 connected thereto) toward end 210BE1 by the deployed articulated link connector 1010A (for example, the movement of finger segments 210S2, 210S3 is subordinate to the movement of finger segment 210S1). Here, finger segments 210S1 to 210S3 are reconfigured as fingers 210AF1 to 210AF3, respectively, and positioned at distances 760'', 760A', and 760A. Similarly, further movement of finger 210S7 toward end 210BE2 in direction LON causes finger 210S7 / slide 1023 to pull slide 1022 (and the finger segments 210S5, 210S6 connected to it) toward end 210BE2 by the deployed articulated link connector 1010B (for example, the movement of finger segments 210S5, 210S6 is subordinate to the movement of finger segment 210S1). Here, finger segments 210S1 to 210S3 are reconfigured as fingers 210AF5 to 210AF7, respectively, and positioned at distances 760B, 760B'', and 760B''. It should be noted that finger segment 210S4 is reconfigured as finger 210AF4. As can be understood, the reconfiguration of finger segments from fingers 210AF1-210AF7 to fingers 210AF1-210AF5 and from 210AF1-210AF5 to 210AF1-210AF3 is carried out in substantially the reverse manner of the above, where the retracting movement of finger segments 210S1 and 210S7 causes finger segment 210S1 to substantially contact finger segment 210S2, pushing finger segments 210S2 and 210S3 toward finger segment 210S4, and finger segment 210S7 to substantially contact finger segment 210AS6, pushing finger segments 210S5 and 210S6 toward finger segment 210S4.

[0053] Referring to Figures 2A, 2B, 2E, 2F, 7A, and 7B, in one or more embodiments, the case handling assembly 210 includes case unit positioning. Here, at least one positioning bar 222, 223 is movable to the payload platform frame 210B in any suitable manner so as to move in direction LON to position the case unit CU in a predetermined position within the payload platform 210B relative to the longitudinal axis LAX of the bot 110. In the illustrated example, there are two positioning bars 222, 223, both of which move in direction LON so as to move at least toward and away from each other, but in other embodiments, one of the positioning bars 222, 223 is stationary and fixed in direction LON, while the other positioning bar 222, 223 moves toward and away from the other positioning bar 222, 223 in direction LON. As described herein, the positioning bars 222, 223 may be driven independently. By independently driving each position adjustment bar 222, 223, the case unit can be positioned at any location within the payload bay 210B. The case unit CU can be positioned off-center (for example, relative to the centerline of the payload platform 210B in direction LAT). Positioning the case unit CU off-center in the payload bay 210B provides continuous, equal spacing between the case units on the storage rack, which improves storage density.

[0054] In one or more embodiments, the position adjustment bars 222, 223 are connected to one or more linear guide rails 225 of the payload platform frame 210BF. In one embodiment, the position adjustment bars 222, 223 are connected to any suitable (one or more) drive motors 226 and (one or more) transmission units 227, similar to the drive motors 275 and transmission units 276 that drive the movable finger segments described herein. For example, in one or more embodiments, a single drive motor 226 drives the motion of both position adjustment bars 222, 2223, where the drive motor 226 is a stepper motor or any other suitable motor connected to a lead screw in a manner similar to the method described above with respect to the finger segments, where one end of the lead screw (e.g., transmission unit 227) is right-handed threaded and the other end of the lead screw is left-handed threaded. Each position adjustment bar 222, 223 includes a nut that engages with one of the right-hand and left-hand threads of the lead screw, respectively, so that when the drive motor 275 rotates the lead screw in a first rotational direction, the position adjustment bars 222, 223 move toward each other (and toward the longitudinal centerline CL of the payload platform 210B), and when the drive motor 275 rotates the lead screw in a second opposite rotational direction (i.e., opposite to the first rotational direction), the position adjustment bars 222, 223 move toward each other (for example, position adjustment bar 222 moves toward the end 200BE1 of the payload platform 210B and position adjustment bar 223 moves toward the end 200BE2 of the payload platform 210B).Here, both position adjustment bars 222, 223 are driven by a single (i.e., the same) drive motor 226 and transmission unit 227 (the drive motor and transmission unit are common to both position adjustment bars 222, 223). In other embodiments, the bot 110 includes two drive motors 226 and at least one transmission unit 227 (i.e., one transmission unit for each position adjustment bar 222, 223 or a common (i.e., one) transmission unit for each position adjustment bar 222, 223), so that each position adjustment bar 222, 223 is driven by its respective motor and transmission unit to move in direction LON independently of the movement of the other position adjustment bar 222, 223 (where the position adjustment of the case unit is not limited to "center position adjustment" relative to the center line CL of the payload platform, but rather the case unit can be positioned at any position between the ends 210BE1, 210BE2 of the payload platform 210B).

[0055] Figures 2E and 2F illustrate an example in which two drive motors 226 are used to move each position adjustment bar 222, 223 independently in direction LON so that the payload CU is positioned somewhere along direction LON within the payload base 210B. In this example, each position adjustment bar 222, 223 includes its respective motor 226, which is connected to a common stationary transmission unit 227, where the transmission unit 227 is a flexible transmission unit similar to the flexible transmission unit 330 described herein. One end of the transmission unit 227 is fixed and connected to the end 210BE1 of the frame 210BF of the payload base 210B by any suitable method (e.g., a clamp, a removable fastener, a clip, etc.). The other end of the transmission unit 227 is fixed and connected to the other end 210BE2 of the frame 210BF of the payload base 210B by any suitable method (e.g., a clamp, a removable fastener, a clip, etc.). The position adjustment bar 222 includes a motor 226 attached to and supported by the position adjustment bar 222 in any suitable manner. The position adjustment bar 222 also includes a drive pulley 226P3 connected to and driven by the motor 226. An idler pulley 226P4 is connected to the position adjustment bar 222 below the drive pulley 226P3 and positioned relative to the position adjustment tray 600 so as to extend at least partially below the payload support surface 610P of the payload bay 210B. The position adjustment bar 223 includes a motor 226 attached to and supported by the position adjustment bar 223 in any suitable manner, a drive pulley 226P1 connected to and driven by the motor 226, and an idler pulley 226P2 connected to the position adjustment bar 223 below the drive pulley 226P1 and positioned relative to the position adjustment tray 600 so as to extend at least partially below the payload support surface 610P of the payload bay 210B.

[0056] The flexible transmission section is wound in a meandering manner around pulleys 226P1, 226P2 and pulleys 226P3, 226P4 such that a portion 227P of the transmission section 227 extends below the payload support surface 610P of the payload bay 210B. The meandering arrangement of the transmission section 227 around pulleys 226P1, 226P2 also results in engagement between the drive pulley 226P1 and the transmission section 227 such that when the motor 226 (of the position adjustment bar 223) rotates the drive pulley 226P1, the position adjustment bar 223 moves in direction LON independently of the movement of the position adjustment bar 222. Similarly, the meandering arrangement of the transmission section 227 around the pulleys 226P3 and 226P4 also results in engagement between the drive pulley 226P3 and the transmission section 227, such that when the motor 226 (of the position adjustment bar 222) rotates the drive pulley 226P3, the position adjustment bar 222 moves in direction LON independently of the movement of the position adjustment bar 223.

[0057] Positioning of the case unit CU on the payload platform 210B in direction LON results in a known position of the case unit CU on the bot 110 that enables the positioning of the case unit CU at a predetermined position in the case unit holding position. Positioning of one or more case unit CUs is performed by at least one position adjustment bar 222, 223 while one or more case unit CUs are held (supported by) on the fingers 210AF of the transport arm 210A, or while one or more case unit CUs are held (supported by) on the position adjustment tray 600. In one or more embodiments, the position adjustment tray 600 includes channels 677, 678 that provide running clearance in direction LON for connection between at least one position adjustment bar 222, 223 and the linear guide rail 225 (and a transmission unit 276 connected to at least one position adjustment bar 222, 223). At least one linear guide rail 225 is exemplified as being located substantially at the center of the payload platform 210B and extending in direction LON, but in other embodiments, at least one linear guide rail 225 is positioned at any suitable position on the payload platform 210B and / or on the transport arm 210A to bring the position adjustment bars 222, 223 to move in direction LON. In one or more embodiments, at least a portion of the position adjustment bars 222, 223 is movable in direction LAT to extend at least partially outside the area bounded by the payload platform 210B.

[0058] Here, the independent movement of the position adjustment bars 222, 223 results in position adjustment of the payload CU at any position along direction LON within the payload platform to provide continuous equal spacing between case units on the storage rack, for example, which improves storage density. As described above, the underpick end effector or transfer arm 210A is used to transfer the payload CU to and from the payload platform 210B at a position adjusted (e.g., in direction LON) using the position adjustment bars 222, 223. In one embodiment, the fingers 210AF of the transfer arm 210A are retracted toward the payload platform 210B along with the payload CU on it to roughly position the payload CU at a predetermined position adjustment position in direction LON. The retraction movement of the finger 210AF and the payload CU on it may be a compound movement in both directions LON and LAT so that the payload CU can be aligned by two degrees substantially simultaneously with the seating of the payload CU on the payload platform 210B and substantially simultaneously with the completion of the retraction movement of the transport arm 210A (as described herein). In one or more embodiments, the support surface 210AFS of the finger 210AF forms a support surface on which the payload CU is aligned by two degrees, where the position adjustment bars 222, 223, pusher 1150, and / or tab 1250 having the finger 210AF perform the alignment of the payload CU by two degrees. With the payload CU seated on the payload stand 210B (for example, seated on the finger 210AF or on the position adjustment tray 600), the position adjustment bars 222 and 223 can be moved independently to fine-tune the position adjustment position of the payload relative to the finger 210AF and the storage position 130S (or other holding position) so that the arrangement of the payload CU in the storage space 130S (or other holding position) by the vehicle 110 maintains the minimum (equal) spacing between aligned payloads in the storage space 130S, thereby improving storage density as described herein.

[0059] Referring to Figures 11A-11C and 12A-12H, each position adjustment bar 222, 223 includes a case pressing assembly 1110 and a case retraction assembly 1120. The case pressing assembly 1110 and the case retraction assembly 1120 are described with respect to position adjustment bar 222, and it should be noted that the case pressing assembly 1110 and the case retraction assembly 1120 of position adjustment bar 223 are substantially similar. Here, position adjustment bar 222 includes slots 1130, 1131 arranged vertically and extending along position adjustment bar 222 in the direction LAT. In Figure 11A, the case pressing assembly 1110 is associated with slot 1130 and the case retraction assembly 1120 is associated with slot 1131, but in other embodiments, such as the embodiment illustrated in Figure 12A, the case pressing assembly 1110 is associated with slot 1131 and the case retraction assembly 1120 is associated with slot 1130. The case pressing assembly 1110 and the case retraction assembly 1120 are used in combination to grip a case unit transported by the bot 110 in one or more embodiments. In one or more embodiments, one or more of the case pressing assemblies 1110 and the case retraction assemblies 1120 are used for positioning the case unit CU in direction LAT, where the case unit is supported by the finger 210AF and / or positioning tray 600. The case retraction assembly 1120 is used to retract the case unit CU into the payload platform 210B in order to substantially prevent the case unit from overhanging (for example, a portion of the case unit extending outside the payload platform 210B through the transfer opening 1199 of the payload platform 210B).

[0060] The pressing assembly 1110 includes any suitable linear actuator 1210 (e.g., a lead screw drive, belt drive, piston, etc., driven by any suitable actuator such as a stepper motor, servo motor, pneumatic device, hydraulic device, etc.) (see Figures 12A, 12B), a slider 1211 connected to the linear actuator 1210 (see Figures 12A, 12B), and a pusher arm or tab 1150 connected to the slider 1211 via a slot 1131 (or 1130, depending on whether the pressing assembly is associated with slot 1131 or slot 1130). The linear actuator 1210 is configured to move the slider 1211 in direction LAT along the channel or slot 1131 in any suitable manner. The pusher arm 1150 is connected to (or integrally formed with) the slider 1211 using any suitable mechanical or chemical fasteners and has a case contact surface 1150S that contacts the side of the case unit CU to push the case unit CU toward the transfer opening 1199 of the payload platform 210B through which the case unit CU passes for transfer to and from the payload platform 210B.

[0061] The retraction assembly 1120 includes any suitable linear actuator 1225 (e.g., a lead screw drive, belt drive, piston, etc., driven by any suitable actuator such as a stepper motor, servo motor, pneumatic device, hydraulic device, etc.), a rotary slider assembly 1230 coupled to the linear actuator 1225, and a pusher arm or tab 1250 coupled to the rotary slider assembly 1230. The linear actuator 1210 is configured to move the rotary slider assembly 1230 in the direction LAT along the slot 1131 in any suitable manner. The rotary slider assembly 1230 includes a non-rotating plug 1231 and a rotary carrier 1232. The retraction arm or tab 1250 is coupled to the rotary carrier 1232 as described herein. The non-rotating plug 1231 is configured to slide linearly in the direction LAT within the channel 1277 of the position adjustment bar 222 under the thrust of the linear actuator 1225. For example, the non-rotating plug 1231 includes a channel engagement portion 1233 having one or more mounting surfaces 1233S (four are shown for illustrative purposes, but in other embodiments there may be more or fewer mounting surfaces, such as one surface illustrated in Figure 12E), and an anti-rotation tab 1234 configured to extend at least partially through a slot 1130 (or slot 1131, depending on which slot 1130, 1131 the rotary slider assembly 1230 is associated with). The engagement between the slot 1130 and the anti-rotation tab 1234 prevents the non-rotating plug 1231 from rotating in a direction 1291 about the rotation axis 1290 within the channel 1277. The non-rotating plug 1231 also includes a carrier engagement portion 1235 configured to bond with the rotary carrier 1232 to enable rotation of the rotary carrier 1232 in direction 1291 and linear motion of the rotary carrier 1232 in direction LAT within the channel 1277, where the rotation and linear motion of the rotary carrier 1232 (and the tab 1250 coupled thereto) are driven by a single motor / linear actuator 1225.The non-rotating plug 1231 is connected to the linear actuator 1225 in any suitable way (e.g., using mechanical and / or chemical fasteners) to reciprocate and slide along the channel 1277 in direction LAT (e.g., connected to one side of the belt / chain loop of the linear actuator 1225, connected to the actuating rod / screw of the linear actuator, connected to the magnetorheological member of the linear actuator 1225, etc.).

[0062] The rotating carrier 1232 includes a tab mounting portion 1260 and a cam portion 1261 connected to (or integrally formed with) the tab mounting portion 1260. The tab mounting portion 1260 is shaped and sized to slide or otherwise pass through a channel 1277. The tab 1250 extends away from the tab mounting portion 1260 and is connected to the tab mounting portion 1260 at the connecting portion 1262 so as to be cantilevered away from the tab mounting portion 1260. The cam portion 1261 is a cylindrical tube having an opening 1263 into which the carrier engaging portion 1235 of the non-rotating plug 1231 is inserted for reciprocating motion within the opening 1263. The cam portion 1260 is exemplified as having an opening 1263 into which the carrier engagement portion 1235 of the non-rotating plug 1231 is inserted, but in other embodiments, the carrier engagement portion 1235 includes an opening and the cam portion 1261 is inserted into the carrier engagement portion 1235 of the non-rotating plug 1231.

[0063] In the embodiment illustrated in Figure 12D, the surface of the opening 1263 includes one or more projections 1263P extending radially inward (for example, toward the rotation axis 1290). The projections 1263P form a cam surface that engages with the corresponding recess 1235R of the carrier engagement portion 1235, where the projections extend helically around the rotation axis 1290 along the length of the opening 1263. The mating recess 1235R extends helically around the carrier engagement portion 1235 and around the rotation axis 1290 to engage with or otherwise mate with the projections 1263P. The projection 1263P and recess 1235R are configured such that movement of the non-rotating plug 1231 in direction LAT1 over a predetermined distance (for example, while the non-rotating plug is held to move in direction LAT1) (such as increasing the amount of the carrier engaging portion 1235 outside the opening 1263) causes rotation of the tab 1250 in direction 1291 about the axis of rotation 1290 at an angle α, as illustrated by the comparison between Figure 12A and Figure 12B, via the cam action of the engaged projection 1263P and recess 1235R. In one or more embodiments, the angle α is approximately 90°, but in other embodiments, the angle α is greater than or less than approximately 90°. As can be understood, the projection 1263P and recess 1235R are configured such that movement of the non-rotating plug 1231 in the opposite direction LAT2 (such as a reduction in a portion of the carrier engaging portion 1235 outside the opening 1263) over a given distance (for example, while the non-rotating plug is held to move in direction LAT2) causes the tab 1250 in the direction 1291 about the axis of rotation 1290 at an angle α via the cam action of the engaged projection 1263P and recess 1235R.

[0064] To enable the rotation of the rotary carrier 1232 relative to the non-rotating plug 1231 (which is held from rotation by the engagement of the anti-rotation tab 1234 and slot 1130), the rotary carrier 1232 is held stationary in direction LAT by stop surfaces 1260S1, 1260S2 of the rotary carrier 1232, at least partially. The stop surfaces 1260S1, 1260S2 extend from the rotary carrier 1232 to engage with one of the stop surfaces 1268, 1269 of channel 1277, respectively. For example, channel 1277 includes a slot or opening 1270 located adjacent to the ends 222E, 223E of the position adjustment bars 222 (and 223) closest to the transfer opening 1199 of the payload platform 210B. Slot 1270 intersects slot 1130. Here, the movement of the non-rotating plug 1231 in direction LAT1 under the thrust of the linear actuator 1225 causes rotation of the stop surfaces 1260S1, 1260S2 (and the tab 1250 of the rotary carrier 1232) toward the slot 1130 in direction 1291A (via cam engagement of one or more protrusions 1263P and corresponding recesses 1235R), where the rotary carrier 1232 is held from movement in direction LAT1 by the engagement of the stop surface 1260S1 of the rotary carrier 1232 with the stop surface 1269 of the channel 1277. The continued rotation of the rotary carrier 1232, enabled by the movement of the non-rotating plug 1231 in direction LAT1, causes the disengagement of the stop surfaces 1260S1, 1269 and the alignment of the stop surfaces 1260S1, 1260S2 with the slot 1130. With the stop surfaces 1260S1 and 1260S2 aligned with the slot 1130, the rotation of the rotary carrier 1232 is prevented (through contact between the stop surfaces 1260S1 and 1260S2 and the side surface 1130S1 of the slot 1130), and the rotary carrier 1232 moves in direction LAT1 together with the non-rotating plug 1231. It should be noted that with the rotation of the rotary carrier 1232 prevented by the slot 1130, the cammed engagement between one or more protrusions 1263P and the corresponding recesses 1235R is locked, resulting in the movement of the non-rotating plug 1231 and the rotary carrier 1232 as a unit in direction LAT.

[0065] To bring about rotation of the stop surfaces 1260S1, 1260S2 (and the tab 1250 of the rotary carrier 1232) in direction 1291B, the linear actuator 1255 moves the non-rotating plug 1231 (and the rotary carrier 1232) in direction LAT2 so that the stop surfaces 1260S1, 1260S2 move into slot 1270 (and disengage from sides 1130S1, 1130S2 of slot 1130) and the stop surface 1260S2 engages with the stop surface 1268 of slot 1270. The engagement of the stop surfaces 1260S2, 1268 stops the movement of the rotary carrier 1232 in direction LAT2, while the disengagement of the stop surfaces 1260S1, 1260S2 from sides 1130S2 of slot 1130 allows the rotation of the rotary carrier 1232 in direction 1291B. With the stop surfaces 1260S2 and 1268 engaged and the stop surfaces 1260S1 and 1260S2 disengaged from the side surface 1130S2 of the slot 1130, further movement of the non-rotating plug 1231 in direction LAT2 under the thrust of the linear actuator 1225 causes rotation of the stop surfaces 1260S1 and 1260S2 (and the tab 1250 of the rotating carrier 1232) away from the slot 1130 in direction 1291B at an angle α (via cam engagement of one or more protrusions 1263P and corresponding recesses 1235R). As described herein, rotation of tab 1250 from a position that may be called a retracted position (shown in Figures 2B, 11A, 12A, and 12E) to a position that may be called an extended position (shown in Figures 2A, 11B, 12B, 12C, 12G, and 12H) orients tab 1250 of position adjustment bars 222, 223 for case unit engagement to pull the case unit held on the payload platform 210B in direction LAT1 (Figures 2A and 11A).

[0066] Referring to Figures 12E to 12H, a portion of the retraction assembly 1120 is illustrated according to an aspect of the disclosed embodiment. Unless otherwise noted, the parts illustrated in Figures 12E to 12H are substantially similar to those described above with respect to Figures 12A to 12D. In Figures 12A–12D, the rotary slider assembly 1230 is configured such that the retracted configuration of the tab 1250 extends toward the vehicle loading surface VRS of the transport deck 130B or picking passage 130A (for example, in direction VERB), while the retracted configuration of the tab 1250 in Figures 12A–12D extends away from the vehicle loading surface VRS of the transport deck 130B or picking passage 130A (for example, in direction VERA). In other embodiments, the rotary slider assembly 1230 is configured such that the retracted position of the tab 1250 is at any suitable position that allows for substantially unobstructed passage of the case unit through the transport opening 1199 (see, for example, Figure 11A), and the tab 1250 is rotated by any suitable rotation angle α that orients the tab 1250 for engagement with the case unit CU as described herein.

[0067] In Figures 12E to 12H, at least one of the stop surfaces 1260S1 and 1260S2 is integrated with the tab 1250. In addition to the stop surfaces 1260S1 and 1260S2, the subsurface of the tab 1250 engages with the surfaces 1268, 1269 and sides 1130S1 and 1130S2 of the slot 1130 in a manner similar to that described above, but note that the stop surfaces 1260S1 and 1260S2 include both the main surface of the tab 1250 for engaging with the surfaces 1268, 1269 of the slot 1270 and the subsurface of the tab 1250 for engaging with the sides 1130S1 and 1130S2 of the slot 1130. In the embodiments shown in Figures 12E-12H, the cammed engagement configuration between the non-rotating plug 1231 and the rotating carrier 1232 is in the form of at least one slot 1286 and at least one pin or post 1287. Here, the cam portion 1261 includes at least one cammed slot 1286, and the carrier engagement portion 1235 includes at least one pin 1287 that engages with at least one slot 1286. In the exemplary embodiments, there are two cammed slots 1286 and two respective pins 1287, but in other embodiments, there may be one or more sets of cammed slots 1286 and pins 1287. When the non-rotating plug 1231 is moved in direction LAT1, the rotating carrier 1232 is held from movement in direction LAT1 by at least one engagement of the stop surfaces 1260S1, 1269 in a manner similar to that described above. The movement of the non-rotating plug 1231 in direction LAT1 causes the relative movement of at least one pin 1287 with respect to at least one slot 1286, enabling the rotation of the tab 1250 and the rotating carrier 1232 in direction 1291 until the rotation of the tab 1250 is blocked in a manner similar to that described above by engagement with one or more of the stop surfaces 1260S1, 1260S2 and one or more of the sides 1130S1, 1130S2 of the slot 1130.When the stop surfaces 1260S1 and 1260S2 are aligned with the slot 1130 and the rotation of the rotary carrier 1232 is prevented, the cammed engagement of at least one pin 1287 and at least one slot 1286 is locked, and the rotary carrier 1232 and the non-rotating plug 1231 move as a unit in direction LAT1 under the thrust of the linear actuator 1225.

[0068] In one or more embodiments, at least one slot 1286 is configured such that the engagement of at least one pin 1287 with the end 1286E of at least one slot 1286 locks the cammed engagement of at least one pin and slot, preventing rotation of the tab 1250 and the rotary carrier 1232. In yet another embodiment, at least one stop surface 1260S1', 1260S2' for holding the movement of the rotary carrier 1232 in direction LAT is integral with the cam portion 1261 and / or tab mounting portion 1260. For example, the tab mounting portion 1260 includes a projection or stop surface 1260S1' that extends beyond the channel 1277 and is substantially in line with the tab 1250, engaging with the outer surface 1293 of the position adjustment bar, to hold the rotary carrier 1232 from moving toward direction LAT1 as the non-rotating plug 1231 moves toward direction LAT1 and the tab 1250 rotates toward direction 1291B. Once the stop surface 1260S1 (and the tab 1250) is aligned with the slot 1130, the rotary carrier 1232 moves toward direction LAT1 together with the non-rotating plug 1231 as described herein (note that rotation between the rotary carrier 1232 and the non-rotating plug 1231 is locked by the engagement of the pin 1287 with the end 1286E of the cammed slot 1286). The stop surface 1260S2' for holding the rotational carrier 1232 moving in direction LAT2 is integral with the cam portion 1261 and engages with the inner surface of the channel 1277 (for example, an end cap 1293C that forms a surface 1293 extending inward beyond the boundary of the channel 1277) (see Figure 12H) to prevent the cam portion 1261 from moving out of the channel 1277 in direction LAT2 (although the tab mounting portion 1260 extends out of the channel 1277).

[0069] In one or more embodiments, the rotary carrier 1232 is held from movement toward direction LAT1 by a retaining mechanism 1222 (e.g., a biased ball or plate) that engages with a portion of the rotary carrier 1232 (e.g., a shoulder 1223), where the engagement of the retaining mechanism with the rotary carrier 1232 results in rotation of the rotary carrier 1232 about axis 1290, while substantially preventing linear motion of the rotary carrier 1232 with respect to the non-rotating plug 1231 toward direction LAT1. By locking a cammed engagement of at least one pin 1287 and at least one slot 1286 (or a cammed engagement of at least one projection 1263P and at least one recess 1235R), the linear actuator 1225 overcomes the biasing force of the retaining mechanism 1222 to move the rotary carrier 1232 toward direction LAT1.

[0070] Illustrative diagrams of the rotation and linear motion of the tabs 1250 described above are illustrated in Figures 11A-11C. The position adjustment bars 222, 223 are moved toward each other in direction LON so as to substantially contact (one or more) case units CU held at least partially within the payload platform 210B. As seen in Figure 11A, the tabs 1250 of each of the respective position adjustment bars 222, 223 are rotated in direction 1291 around their respective axis of rotation 1290 (for example, via relative movement between the non-rotating plug 1231 and the rotating carrier 1232, enabled by their respective linear actuators 1225) from a retracted position (Figure 11A) to an extended position (Figure 11B). The linear actuators 1225 of each of the respective position adjustment bars 222, 223 continue to operate so that the non-rotating plug 1231 and the rotating carrier 1232 (e.g., the rotating slider assembly 1230) are moved as a unit in direction LAT1 so as to pull the case unit into the payload platform 210B. The movement of the rotating slider assembly to direction LAT2 and the rotation of the tab 1250 from the extended position to the retracted position are performed in substantially the opposite manner.

[0071] Referring to Figures 13A to 13F, in one or more embodiments, the retraction assembly 1120 is substantially similar to the one described above, but instead of the rotary slider assembly 1230, the retraction assembly includes a sliding rack assembly 1320. The sliding rack assembly 1320 is described with respect to the position adjustment bar 222, but it should be understood that the position adjustment bar 222 is configured similarly (however, in some embodiments, the position adjustment bar 222 includes the sliding rack assembly 1320, and the position adjustment bar 223 includes the rotary slider assembly 1230, or vice versa).

[0072] The sliding rack assembly includes a sliding frame 1332 which is shaped and sized to reciprocate in the directional LAT within a slot 1130 (or slot 1131). In the illustrated embodiment, the sliding frame 1332 has a rectangular cross-section (and the slot 1130 or 1131 has a mating cross-section), but in other embodiments, the sliding frame 1332 and the slot 1130 (or slot 1131) have any suitable mating cross-section that allows the sliding frame 1332 to reciprocate in the directional LAT. The sliding frame 1332 includes a first end 1332E1 and a second end 1332E2. The sliding frame 1332 includes a channel 1332C (Figure 13D) which extends through at least a portion of the sliding frame 1332 and opens through the first end 1332E1. The rack gear 1331 extends through channel 1332C so as to reciprocate in direction LAT within the channel, where the rack gear 1331 extends out of channel 1332C at a first end 1332E1 for connection with the linear actuator 1225. As seen in Figure 13E, the rack gear 1331 includes a frame 1331F, a gear portion 1331R connected to the frame 1331F, and a stepped portion 1331P.

[0073] A rotary gear set 1378 is connected to a sliding frame 1332 at or adjacent to a second end 1332E2 around an axis 1377. The rotary gear set 1378 includes at least one pinion gear 1351, 1352, 1353 (see Figure 13D). In the illustrated example, at least one pinion gear 1351, 1352, 1353 is three pinion gears stacked vertically (or integrally formed with each other). Here, the lower pinion gear 1351, the intermediate pinion gear 1353, and the upper pinion gear 1352 are connected around an axis 1377 between tines TN1, TN2 of the sliding frame 1332 (Figure 13D). It should be noted that the terms upper, lower, and intermediate are used herein for convenience only, and any other spatial identifiers may be used instead. The rack gear 1331 is aligned with the intermediate pinion gear 1353 so that the gear portion 1331R engages with the intermediate pinion gear 1353 to drive the upper pinion gear 1352 and the lower pinion gear 1351 to rotate. The upper pinion gear 1352 and the lower pinion gear 1351 are aligned with and engage with their respective rack gears 1350R1 and 1350R2, which are mounted on (or integrated with) the tab 1350 as described herein.

[0074] As best seen in Figures 13C and 13D, the tines TN1, TN2 of the sliding frame and the rotary gear set 1378 form a channel through which the tab 1350 reciprocates in direction LON. For example, the tab 1350 includes side LS1, LS2 and longitudinal ends LT1, LT2 (see Figure 13C). The tab 1350 includes a projection 1350P extending at least partially from side LS1 into a slot TNS formed by the tines TN1, TN2 at the second end 1332E2 of the sliding frame 1332. The slot TNS and projection 1350P are sized relative to each other so that the slot TNS at least partially guides the reciprocating motion of the tab 1350 in direction LON. Side LS2 includes at least one rack gear 1350R1, 1350R2 that mesh with at least one pinion gear 1351, 1352, 1353. In the example shown, the upper rack gear 1350R1 meshes with the upper pinion gear 1352 and the lower rack gear 1350R2 meshes with the lower pinion gear 1351 such that the rotation of the upper pinion gear 1352 and the lower pinion gear 1351 causes the tab 1350 to move in direction LON. The dual rack gears 1350R1 and 1350R2 maintain the alignment of the protrusion 1350P within the slot TNS.

[0075] In a manner similar to that described above, the reciprocating motion of the tab 1350 in both directions LON and LAT is brought about by a single linear actuator 1225. For example, Figure 13A illustrates the tab 1350 in the retracted position, and Figure 13B illustrates the tab 1350 in the extended position. Figure 13C illustrates the movement of the extended tab 1350 in the LAT direction. Here, in order to extend the tab 1350, the linear actuator 1225 is operated to move the rack gear 1331 in the LAT direction 1. The movement of the rack gear 1331 in direction LAT1 causes the rotary gear set to rotate in a first rotational direction 1377R1 around axis 1377, where the rotation of the upper pinion gear 1352 and lower pinion gear 1351 in the first rotational direction 1377R1 causes the rack gears 1350R1, 1350R2 (and tab 1350) to move in direction LON1, extending tab 1350. In a manner similar to that described above, the sliding frame 1332 is held from the movement in direction LAT1 so that the rack gear 1331 moves relative to the sliding frame 1332, resulting in the extension of tab 1350.

[0076] The sliding frame 1332 is held in place of movement so that the movement of the rack gear 1331 toward direction LAT1 causes the tab 1350 to extend. As described herein, the extension of the tab 1350 releases the sliding frame 1332 for movement toward direction LAT1, and further movement of the rack gear 1331 toward direction LAT1 causes the rack gear 1331 and the sliding frame 1332 (and tab 1350) to move toward direction LAT1 as a single unit (see Figure 13C). Here, the sliding frame 1332 is held from movement in any suitable manner, such as by one or more of the following: a return mechanism 1222 substantially similar to that described above and a rigid stop engagement (e.g., abutting) between the tab 1350 and the position adjustment bar 222 (note that the position adjustment bar 222 includes a shroud 222S that at least partially surrounds the sliding rack assembly 1320, where the shroud 222S forms part of the channel 1277). In the illustrated example, the shroud 222S includes a stop surface 1366 (Figures 13C and 13F) that substantially abuts against the side surface LS of the tab 1350 when the tab 1350 is at least in the retracted position. The stop surface 1366 includes a projection 1367 that extends into and along the length of the channel 1277. As tab 1350 is extended, the side LS1 of tab 1350 rests along the stop surface 1366 until tab 1350 extends beyond projection 1367 (as shown in Figure 13F) (so that the sliding frame 1322 is held from movement in direction LAT1). The extension of tab 1350 beyond projection 1367 on the stop surface 1366 releases the sliding frame 1322 (and tab 1350) from movement in direction LAT1. As can be understood, the intermediate pinion gear 1353 has a diameter that prevents interference with the portion of projection 1367 that extends along channel 1277 (and the upper pinion gear 1351 and lower pinion gear 1352 are positioned above and below projection 1367, respectively).

[0077] In one or more embodiments, the running clearance and / or lubrication between the sliding frame 1332 and the channel 1277 is such that any friction between the sliding frame 1332 and the channel 1277 is insufficient to cause relative movement between the rack gear 1331 and the sliding frame 1332 (for example, preventing further extension of the tab 1350). In one or more embodiments, a clutch is provided on the rotary gear set 1378 and / or a return mechanism (substantially similar to the return mechanism 1222) is provided between the sliding frame 1332 and the rack gear 1331 such that the force required to cause relative movement between the sliding frame 1332 and the rack gear 1331 is greater than the frictional force between the sliding frame 1332 and the channel 1277. In one or more embodiments, relative movement between the rack gear 1331 and the sliding frame 1332 is prevented by appropriate rigid (e.g., contacting) stops between the surface of the rack gear 1331 in the channel 1332C (e.g., a protruding surface or stepped portion 1331P, etc.) and the mating stop surface (e.g., a stepped surface 1332CS, etc. (Figure 13D)). In yet another embodiment, the above is combined in any suitable manner such that there is substantially no relative movement between the rack gear 1331 and the sliding frame 1332.

[0078] The movement of the tab 1350 from the extended position to the retracted position is performed in substantially the reverse manner of the method described above. For example, a linear actuator operates to move the rack gear 1331 in direction LAT2. The contact of the tab 1350 with the projection 1367 prevents the tab 1350 from moving in direction LON2, and substantially locks (for example, prevents) the relative movement between the rotary gear set 1378 and the rack gear 1331, so that the sliding frame 1332, the rack gear 1331, the rotary gear set 1378, and the tab 1350 (for example, the sliding rack assembly 1320) move in direction LAT2 as a unit. Here, the (one or more) rack gears 1350R1, 1350R2 of the tab 1350, which mesh with the pinion gears 1351, 1352 of the rotary gear set 1378, prevent the rotary gear set 1378 from rotating and prevent relative movement between the rack gear 1331 and the rotary gear set 1378 through the meshing of the rack gear 1331 and the pinion gear 1353. The sliding rack assembly 1320 continues to move in direction LAT2 until the tab 1350 moves through the projection 1367 (and stop surface 1366), at which point the movement of the sliding frame 1332 into direction LAT2 is blocked in any suitable way and the relative movement between the rack gears 1331, 1350R1, 1350R2 and the rotary gear set 1378 is released so that the rack gear 1331 continues to move in direction LAT2 relative to the sliding frame 1332. The movement of the rack gear 1331 relative to the sliding frame 1332 in direction LAT2 causes the rotary gear set 1378 to rotate in direction 1377R2. The rotation of the rotary gear set 1378 in direction 1377R2 causes the tab 1350 to move in direction LON2 so that the tab 1350 is moved to the retracted position. The movement of the sliding frame 1332 in direction LAT2 is prevented in one or more embodiments by a suitable rigid (e.g., contacting) stopper between the surface of the sliding frame 1332 and the channel 1277, by the retaining mechanism 1222 (Figure 12H), or by any other suitable method.The retracted position of the tab 1350 is set in one or more embodiments by the end of the stroke of the linear actuator 1225 in direction LAT2, the end of the stroke being defined by one or more of the following: a hard stop (the linear actuator's current sensor detects when it reaches the hard stop), an encoder position, a switch, etc., where the linear actuator 1225 is controlled by a bot controller 1220 (Figure 1) etc. in response to signals received from one or more sensors / switches indicating the end of the stroke.

[0079] Referring to Figures 2A–2D, 9A, 14A–14F, and 16, at least the case unit support surface 610, the pusher arms 1150, 1250, and the position adjustment bars 222, 223 form a plurality of payload registration facets, which are mounted on the frame 200F to engage with a payload held in the payload base 210B as described herein. The plurality of payload registration facets are arranged to provide at least two degrees of registration to capture and secure the payload in a predetermined position in the payload bay 210B when they engage with the payload, and are configured to result in payload engagement with at least two degrees of registration that aligns the payload substantially simultaneously with the seating of the payload on the payload support surface 610P of the payload bay 210B. In one or more embodiments, seating of the payload or case unit CU on the payload support surface 610P is brought about by an end effector or common seating motion between the arm 210A and the payload support surface 610P for each of the picks of the arm 210A from each of the different support surface heights CUSH1, CUSH2 (see Figure 16) of the storage space 130S. The common seating motion is brought about by moving both the arm 210A and the payload support surface 610P in a common direction VER (e.g., VERU, VERB) using the lift towers 211, 212 as described herein (where the position adjustment tray is blocked by the frame 200F as described herein). The common seating motion is the minimum or minimized motion (for example, in a limited direction VER to allow movement of the case unit CU on the arched support surface 621 of the positioning tray 600) at payload pick heights PCKH1, PCKH2 of the underpick end effector 210A for each of the different support surface heights CUSPH of the storage space 130S.

[0080] As described herein, by causing at least two degrees of alignment of the case unit CU substantially simultaneously with loading the case unit CU into the payload bay 21B, for each case unit CU to be loaded onto the vehicle 110, the commencement of movement of the vehicle 110 (transportation of the loaded case unit CU) is substantially simultaneously with loading the case unit onto the vehicle 110. As an example, the picking operation of an exemplary case unit of bot 110 within a picking passage 130A is described according to the embodiments described herein. It should be understood that the picking operation of a case unit of bot 110 on a transport deck is substantially similar. As described herein, the picking passage includes rails 1600 (and / or solid deck) on which bot 110 moves. Each level 130L of the storage structure includes rails 1600 that provide bot 110 on its level 130L with access to the storage position 130S of the case unit support 900 within the picking passage 130A. As shown in Figure 16, each level 130L includes at least one level of case unit support 900 accessible from the rail 1600 of the respective level. For example, level 130L1 includes a single level of case unit support 900 accessible from rail 1600L1, while level 130L2 includes two levels of case unit support 900 accessible from a common rail 1600L2 (i.e., rail 1600L2 is common to both the upper and lower case unit support 900U, 900L of level 130L2, so that bots 110 on the common rail 1600L2 can access both the upper and lower case unit support 900U, 900L).

[0081] A bot 110 on a predetermined level 130L is commanded by a control server 120 or a warehouse management system 2500, etc., to pick a predetermined case unit CU. The bot 110 moves along a transport deck 130B on the predetermined level 130L to a picking passage 130A where the case unit CU is located, where the movement of the bot and the bot's pick / placement operations are under the control of, for example, a bot controller 1220 or another appropriate controller communicating with the bot 110. The bot 110 is configured, as described herein, to load a payload or case unit CU at predetermined pick heights PCKH1, PCKH2 of the articulated underpick end effector or arm 210A, which extends and retracts (for example, in direction LAT) to load the payload or case unit CU at, for example, predetermined pick heights PCKH1, PCKH2 of the articulated underpick end effector 210A (corresponding to, for example, predetermined case unit support heights CUSH1, CUSH2 of case unit support sections 900, 900U, 900L). In one or more embodiments, each pick height of the end effector 210A is selectable from a variety of predetermined pick heights, and the payload support surface 610P is positioned such that the seating of the payload CU is substantially constant and independent of the pick heights PCKH1, PCKH2 of the articulated underpick end effector 210A, and loads the payload CU. In one or more embodiments, each pick height PCKH1, PCKH2 is selectable from different predetermined pick heights PCKH1, PCKH2, and the payload alignment surface aligns the loaded payload CU (and dealigns the unloaded payload) and loads (or unloads) the payload CU, independently of or unrelated to the pick heights PCKH1, PCKH2 of the articulated underpick end effector 210A.As shown in Figure 16, the articulated underpick end effector 210A extends and retracts to load payloads CU at different heights within the vertical array of storage shelves VAS (from the base level BLA of the vertical array of storage shelves VAS), with the payload alignment plane aligning the loaded payloads CU (and unaligning the unloaded payloads) independently of or regardless of the payload storage shelf heights CUSH1 and CUSH2. Here, the payload support surface 610P is movable relative to the frame 200F with at least one degree of freedom (for example, at least in direction VER) depending on the operation of the articulated underpick end effector 210A relative to the frame 200F, and / or the payload support surface 610P is movable relative to the pick heights PCKH1, PCKH2 of the articulated underpick end effector 210A (see Figures 6A-6F, for example, when the movement of the position adjustment tray 600 is blocked by the frame 200F or moved in direction VERT by the actuator 666A).

[0082] As an example of the pick / placement operation described above, bot 110 on level 130L1 enters the picking passage 130A and stops in the picking passage 130A at the position of case unit CU by any appropriate bot odometry and / or sensor guidance (Figure 18, block 1800). The distance between fingers 210AF (or finger segments 210S1-210S7) is adjusted according to the size of the case unit in the manner described herein. The distance between fingers 210AF (or finger segments 210S1-210S7) is adjusted on-the-fly while bot 110 is moving to the case unit CU storage position 130S and / or when bot 110 is stopped adjacent to the storage position 130S of case unit CU. As seen in Figures 9A and 14A, finger 200AF is aligned with slat 900S of the picking passage storage position 130S so that finger 210AF is moved / extended in direction LAT2 and positioned below case unit CU (Figure 18, block 1810).

[0083] In the manner described above, the finger 210AF is moved in direction VERU to predetermined pick heights PCKH1, PCKH2 in order to pick (or place) the case unit CU from (or to) the storage position 130S. Here, the finger 210AF is moved in direction VERU by the lift towers 211, 212 lifting the payload platform 210B (and its payload support surface 610P). With the case unit CU supported on the finger 210AF, the finger 210AF is moved / retracted in direction LAT1 to transfer the case unit CU to the payload platform 210B (for example, moved / extended in direction LAT2 to transfer the case unit CU from the payload platform 210B). Here, the payload alignment surface is configured to load into the payload bay 210B by enabling engagement of the payload or case unit CU through at least two alignments (as described herein) that align the payload substantially simultaneously with the arm 210A that positions the case unit CU on the payload contact support surface 610. For example, as described above, the distance or gap CAG between the case unit support surface 210AFS of the finger 210AF and the arched support surface 621 of the positioning tray 600 is limited (i.e., minimized) to the extent that it allows for the non-contact movement of the case unit CU on the arched support surface 621. Here, the seating of the case unit CU on the positioning tray 600 is substantially very close to the positioning of the underpicked case unit CU in the payload bay 210B by the end effector 210A, and loading into the payload bay 210B.For example, the required movement of the payload platform 210B and the finger 210AF carried by the payload platform toward direction VERL is minimized such that the arched support surface 621 protrudes above the case unit support surface 210AFS of the finger 210AF, and is performed (completed) substantially immediately after the movement of the payload platform 210B and the finger 210AF toward direction VERL (for example, when the movement of the position adjustment tray is blocked by the frame 200F), and in other embodiments, the actuator 666A causes a movement that causes the arched support surface 621 to protrude above the case unit support surface 210AFS of the finger 210AF. Here, the seating of the case unit or payload CU on the arched support surface 621 of the support surface 610 (i.e., the position adjustment tray 600 support surface 610) aligns the payload CU by 2 degrees of alignment (e.g., in the vertical direction VER and the planar direction LON / LAT) substantially simultaneously with the completion of the retraction of the finger 210AF into the payload platform 210B. The arched support surface 621 is configured to stably hold the payload and to allow the vehicle 110 to begin transiting motion (for example, along the picking passage 130A or the transport deck 130B) substantially simultaneously with the seating of the payload on the positioning tray 600.

[0084] As the case unit or payload CU is seated on the positioning tray 600, and substantially simultaneously with the positioning of the case unit CU on the support surface 610 of the positioning tray 600 (and while the vehicle is already moving along the picking aisle 130A or transport deck 130B), the positioning bars 222, 223 are moved to direction LON so as to be positioned adjacent to each side of the case unit CU. The movement of the positioning bars 222, 223 may be initiated in direction LON before or after the case unit is transported to the payload platform 210B. If the positioning bars 222, 223 are moved to direction LON and adjacent to each side of the case unit CU before the case unit CU is transported to the payload platform 210B, the positioning bars 222, 223 are moved based on the expected size of the case unit to be picked.

[0085] It should also be noted that the tab 1250 extends but is in a retracted position as shown in Figure 14A, etc. (Figure 18, block 1820), enabling substantially unobstructed transport of the case unit CU into the payload platform 210B using the transport arm 210A in a manner similar to the method described above (Figure 18, block 1830). See also Figures 17A and 17B, when the case unit CU is in the payload platform 210B and substantially simultaneously with the positioning of the case unit CU on the support surface 610, the tab 1250 is rotated in direction 1291 around its respective pivot axis 1290 to extend the tab 1250 to the case unit engagement position, as illustrated in Figure 14B. Tab 1250 is moved in direction LAT1 in the manner described above so that the case unit CU is retracted into the payload platform 210B as shown in Figure 14C, thereby correcting any case overhang (for example, a condition in which the case unit CU extends at least partially out of the payload platform 210B and over the cantilevered tip of the payload platform frame 210BF and / or finger 210AF (see Figure 17A)).

[0086] An overhang of the case may exist when the vehicle 110 picks a case unit CU from a "deep" picking position (a deep picking position may be a position on a storage shelf where the predetermined storage position of the case unit partially extends beyond the physical reach of the transfer arm 210A, but only to the extent that the case unit CU in the "deep" picking position can still be stably picked and positioned by the transfer arm 210A). The overhang of the case may be such that the case unit CU may come into contact with the storage structure when the vehicle 110 travels along the picking passage 130A or the transfer deck 130B. Here, when the case unit CU is retracted into the payload platform 210B, the tab 1250 engages with the case unit CU substantially simultaneously with the alignment of the case unit CU on the support surface 610 by two alignments, and substantially simultaneously with the seating of the case unit CU on the support surface 610 to facilitate the passage of the vehicle 110, as described herein (see Figure 17B), thereby substantially eliminating the protruding position of the case and retracting the case unit into the payload platform 210B (Figure 18, block 1840). As can be understood, with the case unit CU seated on the payload platform 210B in two alignments, the tab 1250 can retract the case unit (for example, from an extended position) into the payload platform 210B just enough to open the storage and retrieval structure, so that the vehicle 110 begins transiting along the picking passage 130A or transport deck 130B substantially simultaneously with the seating of the case unit on the payload platform 210B, and immediately thereafter (Figure 18, block 1850).

[0087] In one or more embodiments, substantially simultaneously with the positioning of the case unit CU on the support surface 610, the pusher arm 1150 is moved in direction LAT2 to push the case unit against the tab 1250 to grip the case unit. Here, the case unit can be aligned by at least 2 degrees from an inclined position illustrated in Figure 2D to a position illustrated in Figure 14C.

[0088] As another example of the pick / placement operation described above, bot 110 on level 130L2 enters the picking passage 130A in a manner similar to that described above and stops in the picking passage 130A at the position of case unit CU (Figure 18, block 1800). The distance between fingers 210AF (or finger segments 210S1 to 210S7) is adjusted according to the size of the case unit in the manner described above. Also, in the manner described above, if bot 110 is on the common rail 1600L2, fingers 210AF are moved in direction VERU to pick case unit CU from one or more storage positions 130S of the upper case unit support 900U and lower case unit support 900L on level 130L2, located at heights CUSH2 and CUSH1, respectively (Figure 18, block 1810). Here, the finger 210AF is moved in direction VERU to a predetermined one or more of the pick heights PCKH1, PCKH2 by the lift towers 211, 212 lifting the payload platform 210B (and its case unit support surface 610P). With the case unit CU supported on the finger 210AF, the finger 210AF is moved / retracted in direction LAT1 to transfer the case unit to the payload platform 210B (and moved / extended in direction LAT2 to transfer the case unit from the payload platform 210B) (Figure 18, block 1830). Here, the payload alignment surface is configured to load into the payload bay 210B with at least two alignments that align the payload substantially simultaneously with the arm 210A that positions the case unit CU on the payload contact support surface 610. Again, the distance or gap CAG between the case unit support surface 210AFS of the finger 210AF and the arched support surface 621 of the position adjustment tray 600 is limited (i.e., minimized) to the extent that it allows for the non-contact movement of the case unit CU on the arched support surface 621.Here, the seating of the case unit CU on the position adjustment tray 600 is substantially very close to the positioning of the case unit CU underpicked into the payload bay 210B by the end effector 210A, as described above, and to the loading into the payload bay 210B. In this example, actuator 666A is used to move the arched support surface 621 so that the arched support surface 621 protrudes above the case unit support surface 210AFS of the finger 210AF. Here, the seating of the case unit or payload CU on the arched support surface 621 of the support surface 610 (i.e., the support surface 610 of the position adjustment tray 600) aligns the payload CU by 2 degrees of alignment (e.g., in the vertical VER and the planar LON / LAT) substantially simultaneously with and substantially immediately thereafter the completion of the retraction of the finger 210AF into the payload base 210B. As described above, the arched support surface 621 is configured to stably hold the payload and to allow the vehicle 110 to begin transiting motion (for example, along the picking passage 130A or the transport deck 130B) substantially simultaneously with the seating of the payload on the positioning tray 600.

[0089] In a manner similar to that described above, substantially simultaneously with the placement of the case unit CU on the support surface 610, the position adjustment bars 222 and 223 are moved in direction LON so as to be positioned adjacent to each side of the case unit CU. The position adjustment bars 222 and 223 may be moved in direction LON before or after the case unit is transferred to the payload platform 210B. If the position adjustment bars 222 and 223 are moved in direction LON and adjacent to each side of the case unit CU before the case unit CU is transferred to the payload platform 210B, the position adjustment bars 222 and 223 are moved based on the expected size of the case unit to be picked. As described above, the tab 1250 is extended when the case unit CU is being transported to the payload platform 210B by the transport arm 210A, as shown in Figure 14A, but can also be extended to a retracted position (Figure 18, block 1820), enabling substantially unobstructed transport of the case unit CU into the payload platform 210B (Figure 18, block 1830). With the case unit inside the payload platform 210B and substantially simultaneously with the positioning of the case unit CU on the support surface 610, the tab 1250 is rotated in direction 1291 around its respective rotation axis 1290 to extend the tab 1250 to the case unit engagement position, as illustrated in Figure 14B. Tab 1250 is moved in direction LAT1 in the manner described above so that the case unit CU is retracted into the payload platform 210B as shown in Figure 14C, substantially correcting / eliminating any case overhang (for example, the case unit CU extends at least partially out of the payload platform 210B to pass the cantilevered tip of the payload platform frame 210BF and / or finger 210AF (see Figures 17A and 17B)) (Figure 18, block 1840). In one or more embodiments, substantially simultaneously with the positioning of the case unit CU on the support surface 610, the pusher arm 1150 is moved in direction LAT2 to push the case unit against Tab 1250 to grip the case unit, where the case unit can be aligned by at least 2 degrees from an inclined position illustrated in Figure 2D to the position illustrated in Figure 14C.

[0090] In one or more embodiments, the positioning bars 222, 223 (for example, located on one of the levels 130L as illustrated in Figure 16 and on a bot 110 that transports the case unit) are moved to direction LON to grasp the case unit CU and / or position it within the payload platform 210B. Figures 14C, 14D, and 14E illustrate central positioning of the case unit, in which the case unit is positioned substantially on or along the centerline CL of the payload platform by the positioning bars 222, 223. However, in other embodiments, the case unit is positioned off-center with respect to the centerline CL. As described above, the case unit CU is moved to direction LON with the case unit CU held in the payload platform 210B, and the case unit CU is supported by fingers 210AF and / or the positioning tray 600. Figure 14E illustrates the placement of the case unit CU on the projection 620 of the adjustment tray 600 for positioning to an off-center position relative to the center line CL (see Figure 14F), where the off-center position still allows the case unit CU to be lifted while all of the fingers 210AF remain substantially below the case unit CU. Placement of the case unit from the adjusted position within the payload platform is performed in substantially the opposite manner to that described above.

[0091] According to aspects of the disclosed embodiments, as described herein, at least two degrees of alignment include alignment on the support surface 610, alignment in direction LON and direction LAT. For example, seating the case unit CU on the payload support surface 610P (e.g., on the positioning tray 600) by the arm 210A results in alignment of the case unit CU with at least two degrees of alignment relative to the bot frame 200F. As described above, the seating of the case unit CU on the payload support surface 610P by the arm 210A is substantially very close to the positioning of the underpicked case unit CU into the payload bay 210B by the end effector, and to the loading into the payload bay 210B. It should be noted that by providing at least two degrees of alignment of the case unit CU substantially simultaneously with loading the case unit CU into the payload bay 21B, regardless of the heights CUSH1, CUSH2 of the case unit support surface CUSPH relative to the bot frame 200F or rail 1600 (i.e., regardless of whether the case unit CU is picked from the upper case unit support section 900U or the lower case unit support section 900L at level 130L), it is possible to enable the vehicle 110 to begin moving (transport of the loaded case unit CU along the picking passage 130A or transport deck 130B) substantially simultaneously with loading the case unit CU into the vehicle 110 (Figure 18, block 1850).

[0092] The placement of the case unit CU onto the support shelf from the autonomous transport vehicle 110 (for example, in the storage space 130S or other suitable location of the storage and retrieval system) can be carried out in substantially the opposite manner to that described above. For example, the autonomous transport vehicle 110 is positioned in a predetermined location adjacent to the storage space 130S (or other holding position) where the case unit CU is to be placed (Figure 19, block 1900). For example, in the placement of the case unit CU to one or more storage positions 130S of the upper case unit support section 900U at level 130L2 positioned at height CUSH2, the tab 1250 is used to maintain the case unit CU in a “retracted position” so that when the case unit CU is lifted to a predetermined pick / placement height PCKH2 (together with the payload platform 210B), the case unit CU does not come into contact with the structure of the storage and retrieval system 100 (for example, a shelf) (see Figure 17C) (Figure 19, block 1910). When the case unit CU is stored / placed in the “deep” storage space 130S, the pusher arm 1150 moves in direction LAT2 (Figure 19, block 1920) to position the case unit in an overhanging position (see Figure 17D) (for example, with the payload platform 210B and transfer arm 210A at a predetermined pick / placement height PCKH2), thereby facilitating the placement of the case unit CU by the transfer arm 210A in the “deep” storage position 130S (Figure 19, block 1930).

[0093] Furthermore, in the manner described above, when the bot 110 is on the common rail 1600L2, the finger 210AF is moved in direction VERU to pick up the case unit CU from one or more storage positions 130S of the upper case unit support 900U and lower case unit support 900L of level 130L2 located at heights CUSH2 and CUSH1, respectively. Here, the finger 210AF is moved in direction VERU to a predetermined one or more of the pick heights PCKH1 and PCKH2 by the lift towers 211 and 212 lifting the payload platform 210B (and its case unit support surface 610P). With the case unit CU supported on the finger 210AF, the finger 210AF is moved / retracted in direction LAT1 to transfer the case unit to the payload platform 210B (and moved / extended in direction LAT2 to transfer the case unit from the payload platform 210B), as illustrated in Figures 14B and 16.

[0094] Still referring to Figure 2C, the autonomous transport vehicle 110 includes a vision system configured to bring about case handling by verifying that the correct sized cases are picked, verifying the dimensions of the cases, and verifying the orientation and position of the cases. The vision system substantially continuously monitors the position of the case unit CU in the payload bay 210B and provides the controller 1220 with updated position data of the case unit CU at any appropriate time interval. Here, the case handling assembly 210 includes one or more of the following: (one or more) case edge detection sensors CED, (one or more) case yaw detection sensors CYD, (one or more) case overhand sensors COH, (one or more) shelf sensors SS, (one or more) three-dimensional image sensors IMF, and an extended camera EXT, each of which is communicably connected to the controller 1220 to notify the controller of the position of the cases / shelf to bring about the picking and placement of the case unit CU as described herein. It should be noted that the term “camera” as used herein includes one or more still or video imaging devices including a two-dimensional camera, a two-dimensional camera having RGB (red, green, blue) pixels, a three-dimensional camera having an XYZ+A definition (where XYZ is the three-dimensional reference frame of the camera, and A is one of radar reflectance, time-of-flight stamp, or other distance-determining stamp / indicator), and an RGB / XYZ camera that includes both RGB and three-dimensional coordinate system information, and that non-limiting examples of these are provided herein.

[0095] The (one or more) case edge detection sensors (CEDs) are any suitable sensors, such as laser measuring sensors, configured to scan the shelves of the storage and retrieval system to verify whether a shelf is clear for placing a case unit CU, or to verify the size and position of a case unit before picking up a case unit CU. Although one case edge detection sensor CED is exemplified on each side of the payload bay 210B, more than two or fewer case edge detection sensors may be positioned at any suitable location on the vehicle 110 so that the vehicle 110 can pass through and scan the case unit CU, with the front end 200E1 leading the direction of vehicle movement, or the rear end / rear end 200E2 leading the direction of vehicle movement.

[0096] The case yaw detection sensor CYD is mounted, for example, inside the payload bay 210B. The case yaw detection sensor is a suitable sensor, such as a laser measurement sensor. The case yaw detection sensor CYD measures the yaw or skew of the case unit CU (see Figure 2D) and is positioned to face or orient itself towards the picked case unit CU in order to notify the controller 1220 of the orientation of the case unit CU.

[0097] One or more case overhang sensors (COH) are, in one embodiment, through-beam sensors having emitters and receivers positioned opposite the payload bay 210B, but in other embodiments, reflective sensors or other suitable detection / proximity sensors may be used. When one or more case overhang sensors (COH) detect a case unit CU / obstacle, the controller 1120 is notified that the case unit is exiting the payload bay 210B and extending through the transport opening 1199.

[0098] The shelf sensors SS are positioned at any appropriate location on the case handling assembly to sense the shelves and verify the position of the shelf hats (see Figure 9A) in order to pick up the case unit CU and position the fingers of the transport arm 210A between the shelf hats. (For example, one sensor is positioned on each side of the payload bay 210B.)

[0099] One or more three-dimensional image sensor IMFs (e.g., time-of-flight cameras, image radar systems, light detection ranging (LIDAR)) are appropriately positioned relative to the payload bay 210B and used to measure the position and orientation of the case unit CU within the payload bay 210B. Although one three-dimensional image sensor IMF is illustrated, more than one three-dimensional image sensor IMFs may be present.

[0100] One or more extended cameras EXT are positioned at the rear of the payload bay 210B (opposite the transfer opening 1199) and positioned so that their field of view is within the payload bay 210B in order to record the picking and placement of case units. One or more extended cameras EXT may be used by the storage and retrieval system controller 1220 or operator to debug and / or teach the picking and placement operations (for example, for the automation of the storage and retrieval system).

[0101] Referring to Figures 2A–2D, 9A, 14A–14F, and 15, exemplary methods are described according to aspects of the disclosed embodiments. In this specification, an autonomous transport vehicle 110 is provided (Figure 15, block 1500). The autonomous transport vehicle has a frame 200F that forms a transport payload area or bay 210B of the vehicle 110, the payload bay 210B including a payload contact support surface 610 that defines a payload support surface 610P (Figure 14E) that supports a payload (e.g., a case unit CU) held within the payload bay 210B as the vehicle 110 passes. The payload bay 210B further includes an (articulated) underpick end effector or arm configured to engage with the payload CU against the payload support surface 610P (as described herein) to underpick it, extend and retract toward the payload bay 210B, resulting in the transfer of the payload to and from the payload bay 210B, and unload and load it into the payload bay 210B. A payload alignment surface (as described herein) is also attached to the frame 200F. The payload CU held in the payload area is engaged with the payload alignment surface (Figure 15, block 1510). The payload alignment surface is positioned to provide at least two degrees of alignment in engagement with the payload CU, capturing and securing the payload CU in a predetermined position within the payload bay 210B, and is configured to result in payload engagement along with at least two degrees of alignment substantially simultaneously with the seating of the payload on the payload support surface 610P of the payload bay 210B. In one or more embodiments, as described herein, the seating of the payload or case unit CU on the payload support surface 610P is brought about by a common seating action between the end effector or arm 210A and the payload support surface 610P for each pick of arm 210A from each of the different support surface heights CUSH1, CUSH2 (see Figure 16) of the storage space 130S.

[0102] The method further includes the step of loading the payload CU into the payload area 210B by using a payload alignment surface to position the payload CU on the payload contact support surface 610, substantially simultaneously with an end effector 210A aligning the payload CU, along with at least two alignments. The method may include the step of aligning the payload CU and the payload alignment surface with respect to the frame 200F of the autonomous transport vehicle 110 by at least one of at least two alignments of the payload CU, with the end effector 210A seating the payload CU on the payload support surface 610P. The method may include the step of aligning the payload CU and the payload alignment surface with respect to the frame 200F of the autonomous transport vehicle 110 by at least one of at least two alignments of the payload CU, with the end effector 210A seating the payload CU on the payload contact support surface 610. The seating of the payload CU on the payload support surface 610P by the end effector 210A is substantially very close to the positioning of the payload CU within the payload area 210B by the end effector 210A and the loading into the payload area 210B. By bringing the alignment of the payload CU at least two degrees substantially simultaneously with the loading of the payload CU into the payload area 210B, it becomes possible to initiate the movement of the vehicle 110 substantially simultaneously with loading the payload CU into the vehicle 110 for each payload CU to be loaded into the vehicle 110.

[0103] According to one or more embodiments of the disclosed embodiments, an autonomous transport vehicle for transporting a payload is provided. A frame forming the transport payload region of the autonomous transport vehicle, wherein the transport payload region includes a payload contact support surface that defines a payload support surface for supporting the payload held within the transport payload region when the autonomous transport vehicle is passing, The frame further includes an articulated underpick end effector configured to engage with the payload, underpick the payload against the support surface, extend and retract relative to the transport payload area, resulting in the transfer of the payload to and from the transport payload area, and unload and load the payload into the transport payload area. The frame is equipped with a plurality of payload alignment surfaces that engage with the payload held in the transport payload area, The multiple payload alignment surfaces are arranged to provide at least two degrees of alignment to capture and secure the payload at a predetermined position in the transport payload area when they engage with the payload, and are configured to bring about engagement with the payload along with the at least two degrees of alignment to align the payload substantially simultaneously with the seating of the payload on the payload support surface in the transport payload area.

[0104] According to one or more embodiments of the disclosed embodiments, the articulated underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the articulated underpick end effector, each pick height being selectable from a plurality of predetermined pick heights, and the payload support surface is positioned such that the seating of the payload is substantially constant and independent of the pick height of the articulated underpick end effector loading the payload.

[0105] According to one or more aspects of the disclosed embodiments, the articulated underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the articulated underpick end effector, each pick height being selectable from a plurality of predetermined pick heights, and the payload alignment surface aligns the loaded payload (and dealigns the unloaded payload) independently of or regardless of the pick height of the articulated underpick end effector loading (or unloading) the payload.

[0106] According to one or more aspects of the disclosed embodiments, the articulated underpick end effector extends and retracts to load the payload at each of the payload storage shelf heights in a vertical array of storage shelves at multiple heights (from the base level of the vertical array of storage shelves), and the payload alignment plane aligns the loaded payload (and dealigns the unloaded payload) independently of or regardless of the payload storage shelf height.

[0107] According to one or more embodiments of the disclosed embodiments, the payload support surface is movable relative to the frame with at least one degree of freedom in response to the operation of the articulated underpick end effector relative to the frame.

[0108] According to one or more embodiments of the disclosed embodiments, the payload support surface is movable relative to the frame with at least one degree of freedom and is movable relative to the pick height of the articulated underpick end effector.

[0109] According to one or more embodiments of the disclosed embodiments, the payload alignment surface is configured to provide payload engagement with at least two alignments that position the payload on the payload contact support surface and align the payload substantially simultaneously with the articulated underpick end effector loading the transport payload area.

[0110] According to one or more embodiments of the disclosed embodiments, the seating of the payload on the payload support surface by the articulated underpick end effector results in alignment of the payload and the payload alignment surface with at least one degree of alignment of the payload relative to the frame, out of the at least two degrees of alignment of the payload.

[0111] According to one or more embodiments of the disclosed embodiments, the seating of the payload on the payload contact support surface by the articulated underpick end effector results in alignment of the payload and the payload alignment surface with at least one degree of alignment of the payload relative to the frame, out of the at least two degrees of alignment of the payload.

[0112] According to one or more aspects of the disclosed embodiments, the seating of the payload on the payload support surface by the articulated underpick end effector is performed by the articulated underpick end effector in substantially close proximity to the load in the transport payload area.

[0113] According to one or more embodiments of the disclosed embodiments, by causing at least two alignments of the payload substantially simultaneously with loading the payload into the transport payload area, it becomes possible for each payload to be loaded onto the vehicle to begin moving substantially simultaneously with loading the payload onto the vehicle.

[0114] According to one or more embodiments of the disclosed embodiments, the articulated underpick end effector is configured to engage with the underside of the payload and pick up the payload from below, thereby enabling the autonomous transport vehicle to transport the payload.

[0115] According to one or more embodiments of the disclosed embodiments, an autonomous transport vehicle for transporting a payload is provided. A frame forming the transport payload region of the autonomous transport vehicle, wherein the transport payload region includes a payload contact support surface that defines the payload support surface of the autonomous transport vehicle that supports the payload held within the transport payload region when the autonomous transport vehicle is passing, The frame further includes an underpick end effector configured to engage with the payload to underpick the payload against the support surface of the storage space, extend and retract relative to the transport payload area to transfer the payload between the support surface of the storage space and the transport payload area, and to unload and load the payload into the transport payload area. The frame is equipped with a plurality of payload alignment surfaces that engage with the payload held in the transport payload area, The multiple payload alignment surfaces are arranged to provide at least two degrees of alignment to capture and secure the payload at a predetermined position in the transport payload area when engaged with the payload, and are configured to provide engagement with the payload along with the at least two degrees of alignment to align the payload substantially simultaneously with the seating of the payload onto the payload support surface in the transport payload area, brought about by a common seating motion between the underpick end effector and the payload support surface.

[0116] According to one or more embodiments of the disclosed embodiments, the common seating motion is the minimum motion to close the (common) clearance gap between the underpick end effector and the payload support surface at the payload pick height of the underpick end effector for each different support surface height of the storage space.

[0117] According to one or more embodiments of the disclosed embodiments, the underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the underpick end effector, each pick height being selectable from a plurality of predetermined pick heights, and the payload support surface is positioned such that the seating of the payload is substantially constant and independent of the pick height of the underpick end effector loading the payload.

[0118] According to one or more aspects of the disclosed embodiments, the underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the underpick end effector, each pick height being selectable from a plurality of predetermined pick heights, and the payload alignment surface aligns the loaded payload (and dealigns the unloaded payload) independently of or regardless of the pick height of the underpick end effector loading (or unloading) the payload.

[0119] According to one or more embodiments of the disclosed embodiments, the underpick end effector extends and retracts to load the payload at each of the payload storage shelf heights in a vertical array of storage shelves at multiple heights (from the base level of the vertical array of storage shelves), and the payload alignment surface aligns the loaded payload (and dealigns the unloaded payload) independently of or regardless of the payload storage shelf height.

[0120] According to one or more embodiments of the disclosed embodiments, the payload support surface is movable with respect to the frame with at least one degree of freedom in response to the operation of the underpick end effector on the frame.

[0121] According to one or more embodiments of the disclosed embodiments, the payload support surface is movable relative to the frame with at least one degree of freedom and is movable relative to the pick height of the underpick end effector.

[0122] According to one or more embodiments of the disclosed embodiments, the payload alignment surface is configured to provide payload engagement with at least two alignments that position the payload on the payload contact support surface and align the payload substantially simultaneously with the articulated underpick end effector loading the transport payload area.

[0123] According to one or more embodiments of the disclosed embodiments, the seating of the payload on the payload support surface by the underpick end effector results in alignment of the payload and the payload alignment surface with at least one degree of alignment of the payload relative to the frame, out of the at least two degrees of alignment of the payload.

[0124] According to one or more embodiments of the disclosed embodiments, the seating of the payload on the payload contact support surface by the underpick end effector results in alignment of the payload and the payload alignment surface with at least one degree of alignment of the payload relative to the frame, out of the at least two degrees of alignment of the payload.

[0125] According to one or more aspects of the disclosed embodiments, the seating of the payload on the payload support surface by the underpick end effector is performed by the underpick end effector in substantially close proximity to the load in the transport payload area.

[0126] According to one or more embodiments of the disclosed embodiments, by causing at least two alignments of the payload substantially simultaneously with loading the payload into the transport payload area, it becomes possible for each payload to be loaded onto the vehicle to begin moving substantially simultaneously with loading the payload onto the vehicle.

[0127] According to one or more embodiments of the disclosed embodiments, the underpick end effector is configured to engage with the underside of the payload, pick up the payload from below, and result in the transfer of the payload by the autonomous transport vehicle.

[0128] According to one or more aspects of the disclosed embodiments, the method is A frame forming the transport payload region of the autonomous transport vehicle, wherein the transport payload region includes a payload contact support surface that defines a payload support surface for supporting the payload held within the transport payload region when the autonomous transport vehicle is passing, The frame further includes an articulated underpick end effector configured to engage with the payload, underpick the payload against the support surface, extend and retract relative to the transport payload area, resulting in the transfer of the payload to and from the transport payload area, and unload and load the payload into the transport payload area. The process of providing a payload alignment surface attached to the frame, The process includes engaging the payload held in the transport payload region with the payload alignment surface, The multiple payload alignment surfaces are arranged to provide at least two degrees of alignment to capture and secure the payload at a predetermined position in the transport payload area when they engage with the payload, and are configured to bring about engagement with the payload along with the at least two degrees of alignment to align the payload substantially simultaneously with the seating of the payload on the payload support surface in the transport payload area.

[0129] According to one or more embodiments of the disclosed embodiments, the articulated underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the articulated underpick end effector, each pick height being selectable from a plurality of predetermined pick heights, and the payload support surface is positioned such that the seating of the payload is substantially constant and independent of the pick height of the articulated underpick end effector loading the payload.

[0130] According to one or more aspects of the disclosed embodiments, the articulated underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the articulated underpick end effector, each pick height being selectable from a plurality of predetermined pick heights, and the payload alignment surface aligns the loaded payload (and dealigns the unloaded payload) independently of or regardless of the pick height of the articulated underpick end effector loading (or unloading) the payload.

[0131] According to one or more aspects of the disclosed embodiments, the articulated underpick end effector extends and retracts to load the payload at each of the payload storage shelf heights in a vertical array of storage shelves at multiple heights (from the base level of the vertical array of storage shelves), and the payload alignment plane aligns the loaded payload (and dealigns the unloaded payload) independently of or regardless of the payload storage shelf height.

[0132] According to one or more embodiments of the disclosed embodiments, the payload support surface is movable relative to the frame with at least one degree of freedom in response to the operation of the articulated underpick end effector relative to the frame.

[0133] According to one or more embodiments of the disclosed embodiments, the payload support surface is movable relative to the frame with at least one degree of freedom and is movable relative to the pick height of the articulated underpick end effector.

[0134] According to one or more embodiments of the disclosed embodiments, the method further includes the step of bringing the payload engagement along with at least two alignments, which position the payload on the payload contact support surface and align the payload substantially simultaneously with the articulated underpick end effector loading the transport payload area.

[0135] According to one or more embodiments of the disclosed embodiments, the method further includes the step of aligning the payload and the payload alignment surface by seating the payload on the payload support surface by the articulated underpick end effector, thereby aligning the payload and the payload alignment surface by at least one degree of alignment of the payload relative to the frame of the at least two degrees.

[0136] According to one or more embodiments of the disclosed embodiments, the method further includes the step of aligning the payload and the payload alignment surface by seating the payload on the payload contact support surface by the articulated underpick end effector, thereby aligning the payload and the payload alignment surface by at least one degree of alignment of the payload relative to the frame, of the at least two degrees of alignment of the payload.

[0137] According to one or more aspects of the disclosed embodiments, the seating of the payload on the payload support surface by the articulated underpick end effector is performed by the articulated underpick end effector in substantially close proximity to the load in the transport payload area.

[0138] According to one or more embodiments of the disclosed embodiments, by causing at least two alignments of the payload substantially simultaneously with loading the payload into the transport payload area, it becomes possible for each payload to be loaded onto the vehicle to begin moving substantially simultaneously with loading the payload onto the vehicle.

[0139] According to one or more embodiments of the disclosed embodiments, the articulated underpick end effector engages with the underside of the payload and picks up the payload from below, resulting in the transfer of the payload by the autonomous transport vehicle.

[0140] According to one or more aspects of the disclosed embodiments, the method is Autonomous transport vehicles, A frame forming the transport payload region of the autonomous transport vehicle, wherein the transport payload region includes a payload contact support surface that defines the payload support surface of the autonomous transport vehicle that supports the payload held within the transport payload region when the autonomous transport vehicle is passing, The frame further includes an underpick end effector configured to engage with the payload to underpick the payload against the support surface of the storage space, extend and retract relative to the transport payload area to transfer the payload between the support surface of the storage space and the transport payload area, and to unload and load the payload into the transport payload area. The process of providing a payload alignment surface attached to the frame, The process includes engaging the payload held in the transport payload region with the payload alignment surface, The multiple payload alignment surfaces are arranged to provide at least two degrees of alignment to capture and secure the payload at a predetermined position in the transport payload area when engaged with the payload, and are configured to provide engagement with the payload along with the at least two degrees of alignment to align the payload substantially simultaneously with the seating of the payload onto the payload support surface in the transport payload area, brought about by a common seating motion between the underpick end effector and the payload support surface.

[0141] According to one or more embodiments of the disclosed embodiments, the common seating motion is the minimum motion to close the (common) clearance gap between the underpick end effector and the payload support surface at the payload pick height of the underpick end effector for each different support surface height of the storage space.

[0142] According to one or more embodiments of the disclosed embodiments, the underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the underpick end effector, each pick height being selectable from a plurality of predetermined pick heights, and the payload support surface is positioned such that the seating of the payload is substantially constant and independent of the pick height of the underpick end effector loading the payload.

[0143] According to one or more aspects of the disclosed embodiments, the underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the underpick end effector, each pick height being selectable from a plurality of predetermined pick heights, and the payload alignment surface aligns the loaded payload (and dealigns the unloaded payload) independently of or regardless of the pick height of the underpick end effector loading (or unloading) the payload.

[0144] According to one or more embodiments of the disclosed embodiments, the underpick end effector extends and retracts to load the payload at each of the payload storage shelf heights in a vertical array of storage shelves at multiple heights (from the base level of the vertical array of storage shelves), and the payload alignment surface aligns the loaded payload (and dealigns the unloaded payload) independently of or regardless of the payload storage shelf height.

[0145] According to one or more embodiments of the disclosed embodiments, the payload support surface is movable with respect to the frame with at least one degree of freedom in response to the operation of the underpick end effector on the frame.

[0146] According to one or more embodiments of the disclosed embodiments, the payload support surface is movable relative to the frame with at least one degree of freedom and is movable relative to the pick height of the underpick end effector.

[0147] According to one or more embodiments of the disclosed embodiments, the method further includes the step of bringing the payload engagement along with at least two alignments, which position the payload on the payload contact support surface and align the payload substantially simultaneously with the articulated underpick end effector loading the transport payload area.

[0148] According to one or more embodiments of the disclosed embodiments, the method further includes the step of aligning the payload and the payload alignment surface by seating the payload on the payload support surface by the underpick end effector, thereby aligning the payload and the payload alignment surface by at least one degree of alignment of the payload relative to the frame, of the at least two degrees of alignment of the payload.

[0149] According to one or more embodiments of the disclosed embodiments, the method further includes the step of seating the payload onto the payload contact support surface by the underpick end effector to align the payload and the payload alignment surface by at least one degree of alignment of the payload with respect to the frame, of the at least two degrees of alignment of the payload.

[0150] According to one or more aspects of the disclosed embodiments, the seating of the payload on the payload support surface by the underpick end effector is performed by the underpick end effector in substantially close proximity to the load in the transport payload area.

[0151] According to one or more embodiments of the disclosed embodiments, by causing at least two alignments of the payload substantially simultaneously with loading the payload into the transport payload area, it becomes possible for each payload to be loaded onto the vehicle to begin moving substantially simultaneously with loading the payload onto the vehicle.

[0152] According to one or more embodiments of the disclosed embodiments, the underpick end effector engages with the underside of the payload and picks up the payload from below, resulting in the transfer of the payload by the autonomous transport vehicle.

[0153] According to one or more embodiments of the disclosed embodiments, an autonomous transport vehicle is provided for transporting the payload. The autonomous transport vehicle is A frame forming the transport payload region of the autonomous transport vehicle, wherein the transport payload region includes a payload contact support surface that defines a payload support surface for supporting a payload held within the transport payload region when the autonomous transport vehicle is passing through the region. At least one lift tower connected to the frame, A movable payload carriage, which is movably mounted on at least one of the lift towers and configured to raise and lower the payload within the transport payload area, A drive section having at least one degree of freedom of motion, connected to the movable payload carriage by a flexible transmission unit, wherein the flexible transmission unit movably connects the movable payload carriage to the at least one lift tower, and the drive section is configured to raise and lower the movable payload carriage relative to the at least one lift tower, comprising: The flexible transmission unit is configured to enable torsional stability of the movable payload carriage and the payload held on the movable payload carriage, with respect to the frame and independently of each of the other joints between the movable payload carriage and the at least one lift tower, other than the flexible transmission unit that connects the movable payload carriage to the at least one lift tower.

[0154] According to one or more embodiments of the disclosed embodiments, the flexible transmission is configured to provide torsional stability of the movable payload carriage over the entire range of motion of the movable payload carriage relative to the at least one lift tower.

[0155] According to one or more aspects of the disclosed embodiments, the flexible transmission unit is configured to provide torsional stability of the movable payload carriage over the range of motion of the movable payload carriage relative to the at least one lift tower, resulting in the transfer of the payload from the movable payload carriage to the payload support rack.

[0156] According to one or more aspects of the disclosed embodiments, the flexible transmission unit is configured to provide torsional stability of the movable payload carriage over the range of motion of the movable payload carriage relative to the at least one lift tower, resulting in the transfer of the payload from the payload support rack to the movable payload carriage.

[0157] According to one or more aspects of the disclosed embodiments, the at least one lift tower includes a guide rail for guiding the movement of the movable payload carriage, and the joint between the guide rail and the movable payload carriage is nondeterministic with respect to the twisted position of the movable payload carriage relative to the guide rail.

[0158] According to one or more aspects of the disclosed embodiments, the autonomous transport vehicle further comprises an end effector movably connected to the movable payload carriage and moved by the movable payload carriage, wherein the end effector is configured to extend and retract relative to the torsionally stable movable payload carriage.

[0159] It should be understood that the foregoing description is merely illustrative of the aspects of the disclosed embodiments. Various substitutions and modifications can be attempted by those skilled in the art without departing from the aspects of the disclosed embodiments. Accordingly, the aspects of the disclosed embodiments are intended to encompass all such substitutions, modifications, and variations that fall within the scope of any claims appended herein. Furthermore, the mere fact that different features are described in different dependent or independent claims does not imply that combinations of these features cannot be used to their advantage, or that such combinations remain within the scope of the disclosed embodiments.

Claims

1. A method for transporting a payload by an autonomous transport vehicle, wherein the method is To provide a frame that forms a transport payload region of the autonomous transport vehicle, wherein the transport payload region includes a payload contact support surface that defines a payload support surface for supporting the payload held within the transport payload region when the autonomous transport vehicle is passing through. To provide an articulated underpick end effector within the transport payload area, wherein the articulated underpick end effector is configured to engage with the payload, underpick the payload from the payload support surface, extend and retract toward the transport payload area, transfer the payload to and from the transport payload area, and unload and load the payload into the transport payload area. To provide a plurality of payload alignment surfaces attached to the frame for engaging with the payload held in the transport payload area, The payload alignment surface provides at least two alignments that capture and fix the payload at a predetermined position in the transport payload area upon engagement with the payload, and the at least two alignments are provided substantially simultaneously such that each of the at least two alignments is substantially simultaneous with the other of the at least two alignments, and the payload alignment surface provides payload engagement along with the provided at least two alignments that align the payload substantially simultaneously with the seating of the payload on the payload support surface of the transport payload area. A method that includes [this].

2. The method according to claim 1, wherein the articulated underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the articulated underpick end effector, each pick height is selectable from a plurality of predetermined pick heights, and the payload support surface is positioned such that the seating of the payload is substantially constant and independent of the pick height of the articulated underpick end effector loading the payload.

3. The method according to claim 1, wherein the articulated underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the articulated underpick end effector, each pick height is selectable from a plurality of predetermined pick heights, and the payload alignment surface aligns the loaded payload independently of or regardless of the pick height of the articulated underpick end effector loading the payload.

4. The method according to claim 1, wherein the articulated underpick end effector extends and retracts to load the payload at each of the payload storage shelf heights in a vertical array of multiple storage shelves at multiple heights, and the payload alignment surface aligns the loaded payload independently of or regardless of the payload storage shelf height.

5. The method according to claim 1, wherein the payload support surface is configured to move with respect to the frame with at least one degree of freedom in response to the operation of the articulated underpick end effector on the frame.

6. The method according to claim 1, wherein the payload support surface is configured to move relative to the frame with at least one degree of freedom, and is configured to move in the direction of the pick height with respect to the pick height of the articulated underpick end effector.

7. The method according to claim 1, wherein the payload alignment surface is configured to provide payload engagement with at least two alignments that position the payload on the payload contact support surface and align the payload substantially simultaneously with the articulated underpick end effector that loads the payload into the transport payload area.

8. The method according to claim 1, wherein the articulated underpick end effector seats the payload on the payload support surface, thereby resulting in alignment of the payload and the payload alignment surface by at least one degree of alignment of the payload relative to the frame, of the at least two degrees of alignment of the payload.

9. The method according to claim 1, wherein the articulated underpick end effector seats the payload on the payload contact support surface, thereby resulting in alignment of the payload and the payload alignment surface by at least one degree of alignment of the payload relative to the frame, of the at least two degrees of alignment of the payload.

10. The method according to claim 1, wherein the seating of the payload onto the payload support surface by the articulated underpick end effector is performed substantially in close proximity to the load in the transport payload area by the articulated underpick end effector, such that the seating operation of the articulated underpick end effector is minimized so that the seating operation is completed substantially immediately.

11. The method according to claim 1, wherein the loading of the payload into the transport payload area substantially simultaneously brings about at least two degrees of alignment of the payload, so that for each payload loaded onto the vehicle, the vehicle can begin to move substantially simultaneously with the seating of the payload on the payload support surface of the vehicle.

12. The method according to claim 1, wherein the articulated underpick end effector is configured to engage with the underside of the payload and pick up the payload from below, thereby enabling the autonomous transport vehicle to transport the payload.

13. A method for transporting a payload by an autonomous transport vehicle, wherein the method is To provide a frame that forms the transport payload region of the autonomous transport vehicle, wherein the transport payload region includes a payload contact support surface that defines a payload support surface of the autonomous transport vehicle that supports the payload held within the transport payload region when the autonomous transport vehicle is passing through. The underpick end effector engages with the payload to underpick the payload against the support surface of the storage space, resulting in the transfer of the payload between the support surface of the storage space and the transfer payload area, and unloading and loading the payload into the transfer payload area. Multiple payload alignment surfaces provide at least two alignments that capture and secure the payload at a predetermined position in the transport payload area, and the at least two alignments are provided substantially simultaneously such that each of the at least two alignments is substantially simultaneous with the other of the at least two alignments, and the payload alignment surfaces provide payload engagement along with the provided at least two alignments that align the payload to the payload support surface in the transport payload area substantially simultaneously with the seating of the payload on the payload support surface, which is brought about by a common seating action between the underpick end effector and the payload support surface, brought about by a common seating action between the underpick end effector and the payload support surface, for each pick of the underpick end effector from each different support surface height of the storage space. A method that includes [this].

14. The method according to claim 13, wherein the common seating motion is the minimum motion to close the clearance gap between the underpick end effector and the payload support surface at the payload pick height of the underpick end effector for each different support surface height of the storage space.

15. The method according to claim 13, wherein the underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the underpick end effector, each pick height is selectable from a plurality of predetermined pick heights, and the payload support surface is positioned such that the seating of the payload is substantially constant and independent of the pick height of the underpick end effector loading the payload.

16. The method according to claim 13, wherein the underpick end effector extends and retracts to load the payload at each of the predetermined pick heights of the underpick end effector, each pick height is selectable from a plurality of predetermined pick heights, and the payload alignment surface aligns the loaded payload independently of or regardless of the pick height of the underpick end effector loading the payload.

17. The method according to claim 13, wherein the underpick end effector extends and retracts to load the payload at each of the payload storage shelf heights in a vertical array of multiple storage shelves at multiple heights, and the payload alignment surface aligns the loaded payload independently of or regardless of the payload storage shelf height.

18. The method according to claim 13, wherein the payload support surface is configured to move with respect to the frame with at least one degree of freedom in response to the operation of the underpick end effector with respect to the frame.

19. The method according to claim 13, wherein the payload support surface is configured to move with respect to the frame with at least one degree of freedom, and is movable in the direction of the pick height with respect to the pick height of the underpick end effector.

20. The method according to claim 13, wherein the payload alignment surface is configured to position the payload on the payload contact support surface and to provide payload engagement with at least two alignments that substantially simultaneously align the payload with the underpick end effector loading the transport payload area.

Images