Systems, apparatus, and methods for high-efficiency logistics towers

Abstract

The storage system includes a three-dimensional structure comprising an array of cells, each containing multiple cells configured to hold individual storage bins for retrieval, the array of cells each forming multiple storage levels of varying heights within the three-dimensional structure. A second set of cells are positioned relative to each other to form multiple vertical shafts positioned within the three-dimensional structure. The storage system includes multiple tower robots positioned on top of the three-dimensional structure. Each tower robot is configured to move laterally on the three-dimensional structure between multiple different locations on the three-dimensional structure (including at least a first position positioned on a first vertical shaft contained within the multiple vertical shafts and a second position positioned on a second vertical shaft contained within the multiple vertical shafts).

Description

Technical Field

[0001] Background of the Invention 1. Field of the Invention The present invention generally relates to a logistic tower-based storage system. Specifically, at least one embodiment relates to a system, apparatus and method for an energy-efficient logistic tower-based storage system.

Background Art

[0002] 2. Discussion of Related Art Today, a wide variety of automation techniques are employed in material handling logistics hubs such as distribution centers, fulfillment centers, and micro-fulfillment centers. Several known techniques employ a three-dimensional grid structure arranged in cells, through which search vehicles operate to access storage units for the storage and retrieval of materials oriented within bins throughout the structure. In many cases, the cells are organized so that vertical columns within the structure are oriented for the operation of search vehicles, allowing the search vehicles to access storage containers in one or more bays (or storage cells) positioned horizontally around the search columns at each level. A three-dimensional grid structure may include multiple vertical search columns, each at a separate level of the structure, with associated bays accessible from around each search column. Generally, a grid position containing a vertical search column, combined with adjacent storage cells accessed via the search column, forms a set of cells within the grid. For example, Figures 1A and 1B show top views, respectively, of two different sets of cells 19 and 29, conventionally employed in a grid structure for material storage. Each of these sets of cells includes an elevator cell 17 and multiple storage cells 21. In Figure 1A, a set of cells 19 includes a total of three storage cells 21, each having one storage cell positioned on three of the four sides of the elevator cell 17. In Figure 1B, a set of cells 29 includes four storage cells 21, each having one storage cell positioned on each of the four sides of the elevator cell 17. In these prior art techniques, a set of cells 19 and 29 includes adjacent storage cells that are single-cell depths. That is, the elevator cell 17 provides access to single cells positioned on each of the three or four sides of the elevator cell 17. According to these techniques, multiple sets of these single-deep sets of cells 19 and 29 are combined to form a grid of cells positioned at various levels of the vertical storage structure.

[0003] The multi-level high-density nature of these vertical storage structures increases the amount of material that can be stored on a single property having a given area or 0.093 square meters (square feet) ("footprint"). However, while these structures increase the storage efficiency or storage density of a given geographic footprint, the inefficiencies remain. For example, Figure 2 provides a top view of a completed level of a conventional vertical storage structure 11 designed with several sets of cells 19 and 29 shown in Figures 1A and 1B, respectively. As observed from above, the storage grid has dimensions of 17 grids × 18 grids. This includes elevator cells 17, storage cells 21 and unoccupied cells 23. Cells 19 and 29 of each associated set are identified by horizontal and vertical lines (e.g., grid robots at each level) indicating the horizontal travel path (or range) of a search device. For example, several sets of cells 19 include an elevator shaft 17 and three single-deep storage cells 21 arranged on three sides of the elevator shaft 17. Several sets of cells 29 include an elevator shaft 17 and four single deep storage cells 21 located on all four sides of the elevator shaft 17.

[0004] Figure 2 shows one level within a multilevel storage array, but the same layout is found at each storage level. This increases the degree of inefficiency by adding more unoccupied space to each level included in the storage array. For example, the 17x18 cell array produced by the single deep storage cells shown in Figure 2 contains 14 unoccupied spaces. A 10-level storage array constructed in this manner contains 140 unoccupied cells.

[0005] Therefore, even if the goal of these vertical storage structures is a compact, high-density footprint, unused and unoccupied cells 23 still arise due to the available geometric shapes when assembling the storage grid 11 by using several sets of cells 19 and 29 as building blocks for the entire array of cells. In addition, the geometric shapes provided by several sets of cells 19 and 29 limit the amount of storage cells that can be accessed by a single search device to a maximum of 4. As a result, the use of conventional single-deep sets of cells 19 and 29 in the storage grid increases the number of search devices required in any given array size.

[0006] Generally, conventional vertical storage structures include a lower level traversed by wheeled robotic carts. These carts operate to transfer material to and from retrieval devices at the bottom of the elevator shaft. These carts also shuttle material between the elevator shaft available in the vertical storage structure and between material drop-off and material pickup locations. These carts require a set of tracks or rails to operate on. In addition, the movement of the carts must be precisely controlled by using complex software logic to avoid collisions and / or delays generated by multiple carts on the same track or in the same vicinity.

[0007] The speed at which the material passes through the logistics hub is important, but the aforementioned shortcomings cannot be avoided by these conventional methods. [Overview of the project] [Means for solving the problem]

[0008] Summary of the Invention Therefore, there is a need for methods to increase the storage density of grid-based material handling logistics hubs. According to some embodiments, the storage density is increased by the geometry of a set of cells employed as a building block containing multiple double-deep sets of storage cells in a selected configuration.

[0009] There is also a need to provide designs that increase the operational efficiency of grid-based material handling logistics towers. According to several embodiments, grid-based material handling logistics towers achieve significant improvements in operational efficiency by including a winch-based elevator system combined with a dynamic conveyor system positioned beneath a multi-level array of storage cells at the pickup location. Some of these embodiments eliminate the need for robotic flatbed carts to shuttle materials beneath the array of storage cells. The elimination of robotic carts can significantly increase the operational speed of material transfer within the material handling logistics tower. The patent applicant has found that, in various embodiments, a combination of a winch-based elevator and conveyor system deployed with array storage cells using 3-bay double deep storage cells can optimize the overall system speed of material handling storage and pickup.

[0010] According to one embodiment, the storage system includes a three-dimensional structure comprising: a first plurality of cells configured to hold individual storage bins for retrieval, wherein an array of the first plurality of cells respectively forms a plurality of storage levels oriented at various heights within a three-dimensional structure; and an array of cells including a second plurality of cells oriented relative to one another to form a plurality of vertical shafts oriented within the three-dimensional structure. The plurality of vertical shafts are configured to allow access to the storage cells contained within the first plurality of cells at each level of the plurality of storage levels. The storage system also includes a material transfer level oriented below the plurality of storage levels. The material transfer level includes a transport system configured to move individual storage bins a) from a drop-off station to a location below the plurality of vertical shafts; and b) from a location below the plurality of vertical shafts to a pickup station. The storage system also includes a plurality of tower robots oriented above the three-dimensional structure. Each of the plurality of tower robots includes a vertical lift system including a bin handler. The plurality of tower robots are configured to move the bin handlers vertically within the plurality of vertical shafts to align the bin handlers with the first plurality of cells at various heights. Each tower robot is configured to move laterally on the three-dimensional structure between multiple different locations on the three-dimensional structure, including at least a first position positioned on a first vertical shaft contained within multiple vertical shafts and a second position positioned on a second vertical shaft contained within multiple vertical shafts.

[0011] According to several embodiments, a tower robot positioned at a first location is configured to position a bin handler within a first vertical shaft adjacent to a first set of storage cells at a selected altitude, which includes a range of altitudes. The first set of storage cells includes at least one inner cell configured to hold individual storage bins for later retrieval. The at least one inner cell includes a first edge positioned directly adjacent to the elevator cell, the first edge from which the bin handler is positioned at the selected altitude, and a second edge positioned opposite the first edge. Once positioned adjacent to the first set of storage cells, the bin handler is configured to retrieve the first storage bin positioned within the at least one inner cell for vertical transport from the selected altitude to a material transfer level (for the release of the first storage bin by the bin handler to the transport system), enabling the first storage bin to move from its location below the first vertical shaft. The tower robot is configured to move across the three-dimensional structure from a first position to a second position in order to access a second vertical shaft to locate a second storage bin and deliver the second storage bin to the transport system.

[0012] According to several embodiments, each of the multiple tower robots is configured to raise and lower an associated bin handler between a fully raised position and a fully lowered position. Each of the multiple tower robots includes multiple wheels configured to engage with a three-dimensional structure and propel the tower robot between multiple different locations on the three-dimensional structure. Furthermore, the lower portion of the storage bin extends beneath the multiple wheels of each tower robot due to the associated bin handler and the storage bin being firmly grasped by the associated bin handler in the fully raised position.

[0013] According to several other embodiments, a set of storage cells includes at least one pair of double-deep storage cells, each containing at least one inner cell and an outer cell. The outer cell contained within the at least one pair of double-deep storage cells is positioned adjacent to the second side of at least one inner cell. Once positioned adjacent to the set of storage cells, a bin handler is configured to retrieve the storage bin positioned within the outer cell for vertical transport from a selected altitude to a material transfer level. The at least one inner cell is one of a plurality of inner cells contained within the set of storage cells, and the outer cell is one of a plurality of outer cells contained within the set of storage cells. A set of storage cells each comprises a set of double-deep storage cells, each double-deep storage cell comprising: a) one of a set of inner cells, each having a first edge positioned directly adjacent to an elevator cell located at a height selected by a bin handler and opposite to each first edge; and b) one of a set of outer cells, each being positioned adjacent to each second edge of each inner cell contained within the set of double-deep storage cells.

[0014] In another embodiment, a method for material storage and retrieval is provided. According to these embodiments, a plurality of storage cells are arranged together at various heights within a three-dimensional structure. The plurality of storage cells are configured to hold individual storage bins for retrieval. A plurality of elevator cells are positioned relative to each other to form a plurality of vertical shafts positioned within the three-dimensional structure. The plurality of vertical shafts are configured to allow access to the storage cells contained within the plurality of storage cells at each of the various heights. A material transfer level is positioned below the plurality of storage cells and the plurality of elevator cells. The material transfer level includes a transport system configured to move individual storage bins for storage and retrieval of material in individual storage bins, a) from a drop-off station to a location below the plurality of vertical shafts; and b) from the location below the plurality of vertical shafts to a pickup station. A plurality of tower robots are positioned above the three-dimensional structure, and each of the plurality of tower robots includes a vertical lift system including a bin handler. The plurality of tower robots are configured to move the bin handler vertically within the plurality of vertical shafts to align the bin handler with the plurality of storage cells at various heights.

[0015] According to these embodiments, each tower robot is configured to move laterally on the three-dimensional structure between multiple different locations on the three-dimensional structure (including at least a first position positioned on a first vertical shaft included within a plurality of vertical shafts and a second position positioned on a second vertical shaft included within a plurality of vertical shafts). The vertical lift system is configured to position a bin handler within a first vertical shaft adjacent to a first set of storage cells at a selected altitude included within a variety of altitudes. Once positioned adjacent to the first set of storage cells, the bin handler is positioned to retrieve the first storage bin positioned within the first set of storage cells for vertical transport from the selected altitude to a material transfer level (for the release of the first storage bin by the bin handler to the transport system), allowing the first storage bin to move from its location below the first vertical shaft. The tower robot is configured to move on the three-dimensional structure from the first position to the second position to access a second vertical shaft for retrieving a second storage bin and delivering the second storage bin to the transport system.

[0016] According to another embodiment, the transport system includes a conveyor system comprising a plurality of motorized conveyor tiles. According to another embodiment, the transport system includes a shuttle system configured to move individual storage bins on a material transfer level. The shuttle system includes a plurality of shuttles configured to traverse a horizontal shuttle grid to accommodate individual storage bins from a bin handler.

[0017] In yet another embodiment, a tower robot is employed having a storage array including a plurality of elevator shafts positioned above a transport system. According to some embodiments, the tower robot includes a frame, a lift system fixed to the frame, and a bin handler assembly coupled to the vertical lift system. The bin handler assembly includes a trolley and a bin handler coupled to the bin handler assembly below the trolley; a pair of wheels extending below the frame; and a drive system configured to rotate the pair of wheels to move the tower robot from a first position on a first elevator shaft included in a plurality of elevator shafts to a second position on a second elevator shaft included in a plurality of elevator shafts, wherein the first elevator shaft is a different elevator shaft from the second elevator shaft.

[0018] According to several embodiments, the lift system is configured to move a bin handler assembly vertically within the first elevator shaft to align the bin handler with a first set of storage cells positioned adjacent to the first elevator shaft. To lower the first storage bin to a transport system for horizontal transport and release the first storage bin to the transport system, the bin handler is positioned adjacent to the first set of storage cells and is configured to operate to locate the first storage bin and move the first storage bin vertically within the first elevator shaft. According to these embodiments, the tower robot is configured to move from a first position to a second position on the storage array, and then to move the bin handler assembly vertically within the second elevator shaft to align the bin handler with a second set of storage cells positioned adjacent to the second elevator shaft, locate the second storage bin, and deliver the second storage bin to the transport system.

[0019] Brief explanation of the drawing The attached drawings are not intended to be drawn to scale. In the attached drawings, each identical or substantially identical component shown in the various drawings is represented by like reference numerals. For purposes of clarity, not every component may be labeled within every drawing.

Brief Description of the Drawings

[0020] [Figure 1A] Shows several sets of cells for use in a material handling storage grid according to a conventional technique. [Figure 1B] Shows several sets of cells for use in a material handling storage grid according to a conventional technique. [Figure 2] Shows a top view of a material handling storage grid according to a conventional technique. [Figure 3A] Shows several sets of cells for use in a material handling storage grid of a logistics hub according to one embodiment. [Figure 3B] Shows several sets of cells for use in a material handling storage grid of a logistics hub according to one embodiment. [Figure 4] Shows a top view of a material handling storage grid of a logistics hub according to one embodiment. [Figure 5] [[ID=2……]]Shows a top view of a logistics hub according to one embodiment. [Figure 6] Shows a perspective view of a logistics hub according to one embodiment. [Figure 7] Provides a top view of a logistics hub according to one embodiment. [Figure 8] Provides a detailed view included within the logistics hub of FIG. 5 according to one embodiment. [Figure 9A] Shows a model set of cells for use in a material handling storage grid of a logistics hub according to one embodiment. [Figure 9B] Shows a model set of cells for use in a material handling storage grid of a logistics hub according to one embodiment. [Figure 10] A partial diagram of a logistics hub according to one embodiment is shown. [Figure 11] This shows a tower robot according to one embodiment. [Figure 12] Figure 11 shows a partial view of the tower robot. [Figure 13] A bin handler according to one embodiment is shown. [Figure 14] A bin handler assembly according to one embodiment is shown. [Figure 15] A plan view of a logistics hub according to one embodiment is shown. [Modes for carrying out the invention]

[0021] Detailed explanation The present invention is not limited in its applications to the details of the construction and arrangement of components described in the following specification or shown in the accompanying drawings. The present invention is capable of carrying out other embodiments and can be carried out or performed in a variety of ways. Furthermore, the language and terminology used herein are for illustrative purposes only and should not be considered limiting. The use of “includes,” “has,” “involves,” and variations thereof is intended to include not only the items listed below, their equivalents, but also additional items.

[0022] Referring to Figure 3A, a top view of a first set of cells 39 for use in a material handling storage grid of a logistics hub is shown according to several embodiments. The first set of cells 39 includes an elevator cell 37 and a plurality of storage cells 31. In the shown embodiments, the first set of cells 39 includes a single storage cell positioned adjacent to the first side of the elevator cell 37 and a double-deep pair of storage cells 45 positioned adjacent to the second side of the elevator cell 37. In this configuration, each cell has a parallelogram shape when viewed from above, and the first and second sides of the elevator cell 37 are positioned adjacent to each other but orthogonal. This provides a first set of cells 39 that has an overall L-shape when viewed from above.

[0023] Referring to Figure 3B, a top view of a second set of cells 49 for use in a material handling storage grid of a logistics hub is shown according to several embodiments. The second set of cells 49 includes an elevator cell 37 and a plurality of storage cells 31. In the shown embodiments, the second set of cells 49 includes a single storage cell 31 positioned adjacent to the first side of the elevator cell 37, a first double-deep pair of storage cells 47A positioned adjacent to the second side of the elevator cell 37, and a second double-deep pair of storage cells 47B positioned adjacent to the third side of the elevator cell 37. In this configuration, each cell has a parallelogram shape when viewed from above. The first and second sides of the elevator cell 37 are positioned adjacent to each other but orthogonal. The third side of the elevator cell 37 is positioned adjacent to and orthogonal to the first side and opposite to the second side. In this embodiment, the second set of cells 49 has an overall T-shape when viewed from above, and the single storage cell 31A is oriented at a 90-degree angle to each of the first double-deep pair of storage cells 47A and the second double-deep pair of storage cells 47B.

[0024] The pair of cells 49 shown in Figure 3B is called a 3-bay double-deep configuration because it includes at least one storage cell on three of the four sides of the elevator cell 37 and includes at least one pair of double-deep storage cells. In the shown embodiment, the pair of cells 49 includes two pairs of double-deep storage cells.

[0025] Referring to Figure 4, a top view of a material handling storage grid in a logistics hub according to several embodiments is shown. In various embodiments, the logistics hub includes a logistics tower having multiple grid levels configured as shown in Figure 4, oriented relative to one another. As described below, a logistics tower constructed with multiple grid levels configured as shown in Figure 4 also includes a material exchange level employed to load newly received material into the logistics hub and to remove material from the logistics hub. The features included within the material exchange level are described in more detail below and may vary depending on whether the logistics hub is a warehouse facility, distribution center, fulfillment center, or micro-fulfillment center. For example, a warehouse or distribution center is configured to bulk drop off and pick up material delivered by tractor trailers or other bulk material howlers. In contrast, a micro-fulfillment center may routinely work with end consumers or last-mile couriers picking up material at the logistics hub.

[0026] For example, as shown and described in U.S. Patent Publication No. 2022 / 0194699, several methods provide a logistics tower-based storage system having a compact footprint provided by a tower configuration and high-speed material handling with a winch-based tower robotic drive system. The disclosure of U.S. Patent Application Publication No. 2022 / 0194699, published June 23, 2022, titled “Logistics Tower,” is incorporated herein by reference in whole.

[0027] In the embodiment shown, the material handling storage grid has dimensions of 16 cell width × 16 cell depth. However, the material storage grid may contain fewer or more storage cells depending on the embodiment. For reference, Figure 4 includes coordinate system A, which includes the x and y axes. In addition, the material handling storage grid may be configured with asymmetric dimensions. For example, in some embodiments, the grid may contain more cells in the x direction and fewer cells in the y direction (and vice versa), depending on the embodiment. That is, the number of cells in the x and y directions does not need to be equal. In addition, the number of cells in either or both the x and y directions may include an odd number of cells in some embodiments.

[0028] In addition, various embodiments of a logistics tower having multiple grid levels configured as shown in Figure 4 also include a vertical search system. These vertical search systems are typically positioned above the uppermost material handling storage grid 41 of the logistics tower. As described below, the vertical search system typically includes a lift system positioned above each row of vertical elevators contained within the logistics tower. The vertical search system typically includes a winch, cable, and robotic bin handler. The overall operation involves raising and lowering the robotic bin handler to select and move storage bins (or "totes") positioned within the logistics tower storage grid array within the logistics tower.

[0029] In the embodiments shown, the grid-level cell structure is formed by using only a plurality of first and second sets of cells 39 and 49, respectively, as shown and described in Figures 3A and 3B. As seen in Figure 4, these two sets of cells 39 and 49 can be employed to construct a grid-level storage array in which every grid location is occupied by a functional element containing either an elevator cell 37 or a storage cell 31. That is, the grid contains no unoccupied space. For reference, in Figure 4, a subset of the first set of cells 39 is shaded in gray, and a subset of the second set of cells 49 is shaded in red.

[0030] The patent applicant recognized the advantage of employing a double-deep storage cell configuration to scale a logistics tower that maximizes efficiency by utilizing 100% of the space. In particular, the demonstrated embodiment employs two sets of cell elements 39 and 49 (L-shaped and T-shaped), each containing at least one double-deep set of storage cells. The method can be generalized as follows with respect to each set of cells containing at least one pair of double-deep storage cells:

[0031] The total number of cells contained within a set of cells = 2 × N (where N is an integer greater than or equal to 2); where Y is equal to the amount of double-deep (DD);

number

[0032] For a set of cells with known quantities, the integer N can be solved using Equation 1, and once N is determined, the value Y can be found using Equation 2. For example, to determine the amount of double deep (DD) pairs in a set of cells containing 4 cells = 4, we solve Equation 1 to determine that N = 2. Equation 2 gives the amount of 1 double deep pair contained within the cells of the 4-cell set, providing building blocks for constructing a storage cell array that maximizes efficiency by removing unoccupied cell locations. As another example, to determine the amount of double deep (DD) pairs in a set of cells containing 6 cells = 6, we solve Equation 1 to determine that N = 3. Equation 2 gives the amount of 2 double deep pairs contained within the cells of the 6-cell set, providing building blocks for constructing a storage cell array that maximizes efficiency by removing unoccupied cell locations. The previous method also scales by removing unoccupied space in both smaller and larger storage arrays than those shown in Figure 4 to maximize the efficiency and increase the storage density of a logistic tower with a selected geometric shape.

[0033] Figure 4 also shows the horizontal reach from each elevator cell 37 within each set of cells 39 and 49 by using a set of crossing reference lines contained within each set of cells. These reference lines show direct paths from the elevator shafts within any set of cells 39 and 49 to each of the storage cells 31, 45, 47A, and 47B contained within the cells of the associated set. A robotic bin handler operating within the elevator shaft of any set of cells 39 and 49 can directly reach each of the single deep storage cells 31 adjacent to the elevator shaft. For each pair of double deep cells 45, 47A, and 47B, a robotic bin handler within the associated elevator shaft can directly reach each of the storage cells within the pair directly adjacent to the elevator shaft 37. Second or far-field storage cells are reached by the robotic bin handler via storage cells positioned between the elevator shaft 37 and the far-field storage cell.

[0034] Referring here to Figure 5, a logistics hub 551 including a multilevel storage array 553 is shown according to several embodiments. In various embodiments, the logistics hub 551 employs multiple double-deep sets of cells. These may include several sets of cells having a 3-bay double-deep configuration. According to the shown embodiments, the logistics hub 551 includes a conveyor grid positioned below the bottom array of storage cells, a material transfer section 555, and a pickup section 559.

[0035] The storage array 553 includes multiple winch-based search systems 561, also known as “tower robots.” Multiple storage bins 565 are employed for storage within the material logistics hub 551. The conveyor grid system includes multiple conveyors (e.g., a first conveyor 567A, a second conveyor 567B, a third conveyor 567C, and other conveyors). The conveyors are assembled using individual conveyor tiles laid out adjacent to one another on the base of the logistics hub 551. In the shown embodiment, conveyor 567 is positioned at the base of the logistics hub below the multilevel storage array 553. Here, conveyor 567 runs in a first direction from below the multilevel storage array 553 through the material transfer section 555 to the pickup section 559, or alternatively, runs in a second direction opposite to the first direction to move storage bins from the pickup section 559 or the material transfer section 555 to below the storage array 553.

[0036] Referring here to Figure 8, the conveyor tiles may include a standard conveyor tile 568 and a right-angle transfer tile 569, a right-angle transfer conveyor tile. According to one embodiment, the standard conveyor tile 568 includes at least one motor-driven roller combined with a plurality of idler rollers. During operation, the standard conveyor tile 568 moves the storage bins along a straight path along the longitudinal axis of the conveyor. The motor may be operated to provide a conveyor tile that can reverse direction. The right-angle transfer tile 569 includes a pair of motor rollers that, when set in place, are positioned perpendicular to the longitudinal axis of the conveyor. The right-angle transfer tile 569 includes motor rollers that operate to shift the travel path of the storage bins by 90 degrees. During operation, the right-angle transfer tile 569 includes an off state, where the tile allows the storage bins to continue following a straight path along the longitudinal axis of the conveyor 567. The right-angle transfer tile 569 also includes an ON state, where the motorized action of the roller directs the bin to deviate perpendicularly from the first conveyor to an adjacent grid positioned within the second conveyor.

[0037] These motorized conveyor tiles 568 and 569 provide a force that selectively moves storage bins 565 positioned on conveyor tiles 567 in a first direction or a second direction 180 degrees opposite to the first direction. When placed adjacent to each other in a linear alignment, the conveyor tiles 567 move the storage bins 565 directly in the first or second direction. This configuration is employed, for example, to form a row of conveyor tiles in a material transfer section 555 positioned below corresponding rows in a storage array 563 including elevator cells. Transfer tiles 569 are employed in the conveyor grid to allow bins to change direction of travel. The conveyor grid assembled from the grid of individual conveyor tiles 568 and 569 allows for rapid motion of storage bins 565, combined with precise control of travel, direction, and speed as the storage bins move from a first location in the logistics hub 551 to a second location in the logistics hub 551. For example, the control system may selectively operate the transfer conveyor tile 569 to move storage bins between conveyors. In various embodiments, this can be accomplished by using tile-by-tile control of the operation of the entire conveyor system.

[0038] Generally, the operation of the logistics hub 551 allows the user to pick up material at one of the selected pickup locations within the pickup section 559. A control system is employed to identify the selected material for pickup, to direct the operation of the winch-based lift system to remove the material (stored in bins) from the storage array 553, and to place the bins onto a conveyor contained within the material transfer section 555. The material transfer section 555 operates to move the bins to the pickup station.

[0039] Referring here to Figure 6, a logistics hub 651 is shown, which includes a movable tower robot 661 according to one embodiment. Each tower robot includes a winch system configured to raise and lower bin handlers. In addition, each tower robot includes several sets of wheels and an electric drive system for supplying power to the several sets of wheels. The logistics hub 651 includes a multi-level storage array 653 and an upper level 677. The multi-level storage array 653 is configured to provide elevator cells positioned above each other to form a vertical shaft from the upper level 677 to a material transfer level positioned at the base of the logistics hub 651. The multi-level storage array 653 also includes storage cells configured to hold storage bins 665. Each tower robot 661 is in communication with a central control system that transmits data, including operation commands, to the tower robot 661. The operation commands provide the information necessary for the tower robot 661 to coordinate its activities within the logistics hub 651 to move storage bins within the multi-level storage array 653.

[0040] Referring to Figure 7, a logistics hub 751 including a mobile tower robot 761 according to another embodiment is shown. Figure 7 provides a top view showing the structure of the upper level 777, on the upper level 777, the tower robot 761 moves between positions on various elevator rows contained within the multi-level storage array 753. These movements are described in further detail below.

[0041] Referring again to Figure 8, a close-up of the storage cart 565, the storage cart structure includes a rim 579. According to several embodiments described in more detail below, the rim 579 is utilized by a locking system contained within the bin handler of tower robots 551, 661, 761, 1061, 1161 to securely grip the storage bins 565 for transport within multi-level storage arrays 553, 653 or the vertical storage grid 1075 in Figure 10, described below. According to the embodiment shown in Figure 8, the rim 579 includes a raised edge that engages more readily with the locking mechanism contained within the bin handler.

[0042] Referring to Figure 9A, a top view of a model cell set 971 for use in a material handling storage grid of a logistics hub according to various embodiments is shown. The model cell set 971 includes an elevator cell 937 and a group of storage cells 931 positioned on three sides of the elevator cell 937 to form an inverted T-shape. In the shown embodiment, each of the three sides includes four-bay storage cells. For example, the first group of storage cells 947A is positioned on the first side of the elevator cell 937, the second group of storage cells 947B is positioned on the second side of the elevator cell 937, and the third group of storage cells 947C is positioned on the third side of the elevator cell.

[0043] The overall configuration of cell 971 in the model assembly is called a 3-bay configuration because the elevator cell 937 accesses storage cells on each of its three sides. In the shown embodiment, each of the first group of cells 947A, the second group of cells 947B, and the third group of cells 947C contains four storage cells, each individually referred to as a "quadset." This configuration can be used in which a tower robot employed with a set of cells is configured to extend over a 4-bay depth in the storage grid. Cell 971 in the model assembly shown in Figure 9A is called a 3-bay quad configuration because it includes at least one storage cell on three of the four sides of the elevator cell 937, which has at least one group of 4-deep storage cells. Although shown as 3 quad groups, other configurations can be employed, for example, each of the three groups 947A, 947B, and 947C could be a double-deep pair of cells and double-deep pairs 45, 47A, and 47B, as shown and described above with reference to Figures 3A and 3B. In various embodiments, other combinations of storage cells may be arranged in various groups around a single elevator cell.

[0044] A group of storage cells within a set of cells is served by a robotic bin handler that is raised and lowered within an elevator cell. Each bin handler is part of a tower robotic vertical search system that raises and lowers the bin handler itself. The bin handler is configured to align vertically with the storage cells within the elevator cell at a selected level, from which it may extend laterally (e.g. horizontally) to reach the storage cells of an adjacent group to the depth required to retrieve (or return) the storage cart to a desired location within the storage array. According to some embodiments, the tower robotic search system includes an upper assembly that includes at least one winch and associated cables employed to raise and lower the bin handler within the elevator shaft.

[0045] As shown and explained with reference to Figures 3A, 3B, and 9A, several sets of storage cells, including a single tower robot location, can be provided in a wide variety of configurations, each having at least one double-deep pair of storage cells. These different double-deep configurations can be used in various combinations to maximize storage cell density by significantly reducing or eliminating unoccupied cell locations within the multi-level storage array.

[0046] Figure 9B shows a variety of different combinations and configurations of cells that may be employed when generating a multilevel storage array. Model cell set 973 includes many sets of cells having at least one set of double-deep storage cells combined with an elevator cell serviced by a tower robot. These include a first 3-bay double-deep configuration 971A having two pairs of double-deep cells positioned on both sides of the elevator cell; a first 2-bay double-deep configuration 971B having two pairs of double-deep cells positioned on adjacent sides of the elevator cell; a second 2-bay double-deep configuration 971C including one pair of double-deep cells and one single-deep cell; a second 3-bay double-deep configuration 971D having two pairs of double-deep cells positioned on adjacent sides of the elevator cell and one single-deep cell on the third side; and a first 4-bay double-deep configuration 971E having three pairs of double-deep cells positioned on three sides of the elevator cell and one single-deep cell on the fourth side. A second 4-bay double deep configuration 971F, comprising a pair of double deep cells, each having a single deep cell positioned on one of the three remaining sides. A third 2-bay double deep configuration 971G, comprising two pairs of double deep cells positioned on both sides of the elevator cell. A first single-bay double deep configuration 971H, comprising a pair of double deep cells. A third 4-bay double deep configuration 9711, comprising two pairs of double deep cells positioned on both sides of the elevator cell and single deep cells positioned on the two remaining sides. A fourth 4-bay double deep configuration 971J, comprising two pairs of double deep cells positioned on adjacent sides of the elevator cell and single deep cells positioned on the two remaining sides. A third 3-bay double deep configuration 971K, comprising a pair of double deep cells, each having a single deep cell positioned on two sides adjacent to a pair of double deep cells. A fourth 3-bay double deep configuration 971L, comprising three pairs of double deep cells. A fourth two-bay double deep configuration 971M having a pair of double deep cells and a single deep cell positioned opposite the double deep cells. A fifth four-bay double deep configuration 971N including four pairs of double deep cells, each positioned on each side of an elevator cell.Cell 973 in the remaining model set shown in Figure 9B does not contain any pair of double deep cells.

[0047] In some embodiments, a storage cell array that maximizes efficiency while satisfying performance requirements is determined by using an array construction design algorithm. This algorithm may employ inputs including a combination of the following: a) desired storage density (e.g., storage array footprint capacity / 0.093 square meters (square feet)); b) desired material handling speed (e.g., maximum transfer time between bin pickup at storage cell location and delivery at pickup station); and c) total available space given the available array height. These three elements (and other elements) may be weighted based on their degree of importance to the particular site and application. For example, if material handling speed is paramount, a higher percentage of single-deep cell sets may be adopted. Conversely, if storage density is paramount, a higher percentage of double-deep cell sets may be adopted. Generally, this method is employed to optimize the selection of different types of cell sets to satisfy project objectives, while eliminating unoccupied space to maximize the efficiency of the logistics tower and increase storage density.

[0048] Referring here to Figure 10, the top level of the multi-level storage array system 1051 in various embodiments is shown. The system 1051 includes a plurality of mobile tower robots (e.g., mobile tower robot 1061). Each tower robot includes a winch system and a bin handler. In addition, each tower robot includes several sets of wheels and an electric drive system for supplying power to several sets of wheels. The system 1051 includes a vertical storage grid 1075 and an upper level 1077. The vertical storage grid 1075 is configured to provide elevator cells positioned above each other to form a vertical shaft extending from the upper level to a material transfer level positioned at the base of the multi-level storage array system 1051. The vertical storage grid 1075 also includes storage cells configured to hold storage bins. Each tower robot 1061 is in communication with a central control system that transmits data, including operation commands, to the tower robot 1061. The operation commands provide the information necessary for the tower robot 1061 to coordinate its activities within the multi-level storage array system 1051 in order to move the storage bins within the storage grid 1075.

[0049] The bin handler contained within each tower robot is raised and lowered as needed to access a bin adjacent to the elevator cell in which the bin handler is operating. Once correctly aligned at the desired level within the storage grid 1075, the carriage contained within the bin handler extends into and from the storage cell to place or remove storage bins at several locations within the grid. As described above, several sets of cells can be provided in a wide variety of configurations designed to maximize efficiency. According to some embodiments, a wide variety of sets of cells, including double-deep configurations, are contained within the storage grid 1075. In these double-deep configurations, the carriage contained within the bin handler may penetrate a storage cell directly adjacent to the elevator cell, in which the bin handler is positioned to access a storage cell that is one cell removed from the elevator cell.

[0050] According to the embodiment shown in Figure 10, the upper level 1077 of the storage grid 1075 includes panels positioned on top of any vertical rows that are not elevator rows. According to other embodiments, the panels are not included in the upper level 1077. Instead, the top of the multi-level storage array system 1051 is an open grid. In various embodiments, a tower robot 1061 is an integrated mobile system that can move horizontally across the entire top of the storage grid 1075 on the upper level 1077 to position itself over various rows. The ability to dynamically reposition the tower robot 1061 can reduce the total amount of tower robots required in the system 1051. The flexibility provided by the self-moving tower robot 1061 can be employed in combination with the techniques shown and described with reference to Figures 3A, 3B, 4 and 9 to provide the most efficient use of the space served by an ideal amount of tower robots. This method also supports larger-scale dynamic reconfigurations of the system, which may include, for example, converting elevator rows into rows of storage cells (and vice versa), without requiring any permanent adjustments to the location of individual tower robots 1061.

[0051] Referring here to Figure 11, an isometric view of a tower robot 1161 according to one embodiment is provided. According to this embodiment, the tower robot 1161 includes a winch system 1120, a bin handler 1122, a frame 1124, a central plate 1126, and a pair of wheels 1128. The winch system 1120 includes a plurality of cable reels 1130, each having associated motors 1132 and linear actuators 1134 to provide vertical travel of the winch system 1120 within the frame 1124. The bin handler includes a carriage which is shown and described in detail below.

[0052] In the shown embodiment, each of the four cable reels 1130 is connected to a different corner of the bin handler 1122 by the cable wound around the reel. The overall operation of the tower robot 1161 when positioned above the elevator row includes raising and lowering the bin handler 1122 for transferring storage containers in the multi-level storage array system 1051. When the bin handler is lowered, the cable is advanced or "fed out" from each reel at the same speed to maintain the bin handler in a certain level orientation. A motor 1132 associated with each reel 1130 rotates the reel in a first rotational direction to advance the cable. The direction of rotation of the motor is reversed to raise the bin handler by retrieving the cable and winding the cable back around the reel. In each case, an actuator 1134 operates to periodically lower and then raise a winch assembly 1120 in the frame 1124 of the tower robot 1061. This vertical movement of the winch assembly, via a limited range of motion, is completed to evenly wind and unwind the cable around the reel.

[0053] According to several embodiments, the bin handler 1122 includes a sensor package (e.g., an inertial sensor package for providing feedback on the pitch and yaw of the bin handler). For example, the sensor package may include one or more accelerometers. The feedback provided by the sensor package is employed by the tower robot control system to control the motor operation as the cable is wound / unwound around the reel so that the bin handler is kept flat. The motor control may work to increase or decrease the speed at which the motor spins as the cable is wound / unwound. This control may be performed uniformly or independently across all four motors / reels if it is necessary to adjust the bin handler back to its original level.

[0054] Each tower robot 1061 and 1161 includes wheels positioned on each of the four sides of tower robot 1161. In various embodiments, the framework provided by the upper level 1077 of the storage grid 1075 provides a rail or track system from which tower robots 1061 and 1161 can move across the entire top of the multi-level storage array system 1051 to position themselves over the desired elevator row. In some embodiments, the rail or track system is an integral part of the storage grid framework. In other embodiments, the rail or track system is a separate hardware system fixed to the storage grid framework. In either method, two pairs of wheels (e.g., a pair of wheels 1128) positioned on the opposing sides of tower robot 1161 engage with the rail / track system to drive tower robot 1161 along the upper level 1077 from a first position over a first elevator row location to a second position over a second elevator row location. This is described in more detail below.

[0055] In various embodiments, the multi-level storage array system 1051 and the tower robot 1161 themselves include various design features to facilitate the mobility of the tower robot 1161. For example, the tower robot control system included within the multi-level storage array system 1051 includes wireless data communication between each tower robot and a central controller. Wireless communication allows the system controller to provide several commands to individual tower robots to initiate movement from a first position to a second position along the upper level 1077. The communication system is used to provide commands for the operation of the bin handler and associated carriage assembly. For example, a tower robot may receive a command to identify a first set of cells on a selection level from which storage bins need to be accessed. The tower robot operates with this information to position the bin handler to move the storage bins from its current location to a conveyor system positioned on the material transfer level of the multi-level storage array system 1051.

[0056] The upper level 1077 of the storage grid 1075 includes location tags using any one of a wide variety of technologies, depending on the embodiment. According to some embodiments, tags suitable for optical scanning are mounted on the storage grid (for example, QR code tags may be employed). In this embodiment, the tower robot 1161 includes a camera-based system or other optical reader configured to read location data from the QR code as the tower robot navigates along the upper level 1077. According to other embodiments, RFID technology is employed. For example, an RFID tag may be located on the upper level 1077 of the storage grid 1075. In this embodiment, the tower robot 1161 includes an RFID reader configured to read the RFID tag to determine the tower robot's current location on the upper level 1077.

[0057] The mobility of the tower robot 1161 is supported by other features of the entire multi-level storage array system 1051. A wireless communication system providing a communication network for bidirectional transfer of information and data between the tower robot 1161 and the central controller is one example. In addition, the tower robot 1161 may include an essential power source that allows the tower robot to operate as it moves across the entire top of the storage grid 1075. According to this embodiment, the tower robot 1161 includes a battery with sufficient capacity to power the drive motors that operate when the tower robot changes location. This embodiment allows the tower robot, including a wireless power connection when it is in place on the elevator row, to operate without any external wired connections during the period when it moves between locations.

[0058] Referring to Figure 12, additional details of the tower robot 1161 in various embodiments are shown. Figure 12 provides a partial view showing three of four reels 1130A, 1130B, and 1130C contained within the winch system 1120, along with two of four cables 1131A, 1131B. The first pair of wheels 1128 is shown together with the second pair of wheels 1129. A third pair of wheels positioned opposite the second pair of wheels 1129 is partially visible (see single wheel 1145 of the third pair of wheels). Figure 12 also provides a partial view of the carriage 1136 contained within the bin handler 1122, showing parts that would otherwise not be obscured by the frame 1124. The two pairs of wheels 1128 and 1129 are coupled to the first wheel frame 1138 and the second wheel frame 1139, respectively. The first drive system 1140 is positioned on top of the first wheel frame 1138. The second drive system 1141 is positioned on top of the second wheel frame system 1139. In addition, the tower robot 1161 includes an actuator 1142 and a drive rod 1143. According to the shown embodiment, the tower robot 1161 is positioned on a storage grid.

[0059] Cables 1131A and 1131B extend from reels 1130A, 1130B, and 1130C to the corners of bin handler 1122, respectively. This configuration allows bin handler 1122 to be suspended within the frame 1124 of tower robot 1161 when not in use. Cables are also employed to suspend bin handler 1122 as it is raised and lowered within the elevator row of multi-level storage array 1051.

[0060] Pairs of wheels (e.g., first and second pairs of wheels 1128, 1129) are positioned on each side of the tower robot 1161. Two pairs of wheels positioned on opposite sides of the tower robot 1161 work together to move the tower robot 1161 in a first horizontal direction and in a second horizontal direction opposite to the first horizontal direction. The other two pairs of wheels are positioned on the remaining two sides of the tower robot 1161, opposite to each other. These two pairs of wheels work together to move the tower robot 1161 in a third horizontal direction and in a fourth horizontal direction opposite to the third horizontal direction. In the shown embodiment, each of the third and fourth horizontal directions is perpendicular to both the first and second horizontal directions. This arrangement allows the tower robot 1161 to move along all four axes of the upper level 1077 of the storage grid.

[0061] Each pair of wheels includes a drive system, which includes a motor and drive linkage, to connect the motor to the wheels contained within the pair of wheels 1128 and 1129. In the shown embodiment, the first drive system 1140 is positioned on the first wheel frame 1138. A belt, chain, or other linkage connects the rotational output of the drive motor to each wheel contained within the pair of wheels 1128. Similarly, the second drive system 1141 is positioned on the second handle frame 1139. Here, the rotational output of the drive motor is coupled to each wheel contained within the pair of wheels 1129 by linkage hardware.

[0062] To allow degrees of freedom of movement for the tower robot 1161 from row to row of the storage grid, each pair of wheels includes a lifting mechanism employed to raise and lower each pair. This technique allows for the temporary disengagement of a pair of wheels from the track or guide rail on which the tower robot 1161 moves. That is, each of several pairs of wheels remains in a lowered position engaged with the guide rail or track when the tower robot 1161 is in a steady position on the upper level 1077 of the storage grid. Each wheel frame is also connected to an actuator via an associated drive rod (e.g., actuator 1142 and drive rod 1143 connected to the first wheel frame 1138). In some embodiments, the actuator includes a motor, and the drive rod couples the motor's rotational output to the wheel frame (e.g., by using a worm gear connection). According to these embodiments, the actuator operates to raise and lower a pair of wheels by raising and lowering the wheel frame.

[0063] Referring to the operating state of the tower robot 1161 shown in Figure 12, the first pair of wheels 1128 are in a raised position where the wheels are disengaged from the storage grid. The second pair of wheels 1129 are in a lowered position where the wheels are engaged with the storage grid. In this operating state, the third pair of wheels (partially shown as represented by a single wheel 1127) are also positioned engaged with the storage grid. In this state, the tower robot 1161 can move along the storage grid in either of two directions. The first direction is generally toward the observer in Figure 12, and the second direction is directly opposite the first direction.

[0064] For explanatory purposes, the operation of the tower robot 1161 is described, hereby placed in a state of motion along the storage grid, generally toward or away from the observer, as observed in Figure 11. The tower robot 1161 begins in a stationary state on the first elevator row (with the bin handler 1122 fully retracted into the frame 1124). In this state, all four pairs of wheels (including the first and second pairs of wheels 1128, 1129) are in a lowered position engaged with the storage grid. The tower robot 1161 begins a change of position by moving the first pair of wheels 1128 and the second pair of wheels positioned opposite the first pair to a raised position (the two pairs of wheels are no longer in contact with the storage grid). With respect to the first pair of wheels 1128, this change of position is achieved by the operation of actuator 1142 to move the entire wheel frame 1138 upward. Similar operation occurs with respect to a pair of wheels positioned on the opposite side of the tower robot 1161 via a combination of another actuator and drive rod positioned on that side.

[0065] With the two pairs of wheels disengaged from the storage grid, separate drive systems associated with each pair of wheels operate to rotate the wheels and move the tower robot 1161 in the desired direction. With respect to the second pair of wheels 1129, the drive system 1140 operates by engaging with an electric linkage to convert the motor's action into rotation of the first pair of wheels 1129. Similar operation occurs with respect to the third pair of wheels 1127, which are positioned on the opposite side of the tower robot 1161 via another drive system positioned on that side. The tower robot 1161 moves along the upper level 1077 of the storage grid until it reaches the desired location on the second elevator row. At this point, the two drive systems are turned off. Actuators operate to lower the wheel frames and mounted pair of wheels of the first pair of wheels 1128 and the pair of wheels positioned opposite the first pair to a lowered position in contact with the storage grid. The tower robot 1161 is now positioned to operate the winch system 1120 as needed to access bins in storage cells adjacent to the second elevator row at any level within the multi-level storage array 1051.

[0066] In various embodiments, the upper level 1077 of the storage grid includes a set of tracks configured for the wheeled movement of the tower robot 1161, so that the wheels of the tower robot 1161 travel between locations on the storage grid. The tracks are also laid out in a grid pattern having intersections at regular intervals to allow the tower robot 1161 to travel in any direction of a plurality of directions. The control system provides navigation commands that allow the tower robot 1161 to travel between two known locations on the tracks without colliding with any of the other tower robots. According to one embodiment, the tracks are formed as an integral part of the structural elements of the upper level 1077 of the storage grid.

[0067] According to various embodiments, the tower robot 1161 includes an integrated power system, including a rechargeable battery, to provide power to at least the drive system (e.g., one or more motors and associated mechanical connections to the wheels) that operates the wheels as the tower robot moves between locations on the storage grid. These self-powered embodiments allow the tower robot 1161 to move between locations without the need to maintain a connection to an external power source when the tower robot is transitioning between locations. According to some embodiments, the tower robot includes contact blocks mounted on a frame 1124. The contact blocks are connected to a rechargeable battery. A corresponding stationary contact block is positioned on the storage grid. The contact block on the storage grid is connected to a power source used to recharge the battery contained within the tower robot 1161. In these embodiments, the two contact blocks complete their electrical connection when, for example, the tower robot 1161 is positioned above the elevator shaft. This provides an opportunity for recharging whenever the tower robot 1161 is positioned above the elevator shaft. According to another embodiment, the integrated power system has sufficient capability to operate the winch system and bin handler in addition to the wheel motor drive system without the need for a fixed connection to an external power source of the tower robot.

[0068] Referring now to Figure 13, a bin handler 1112 according to one embodiment is shown. The bin handler 1122 includes a base 1152, a first extension 1153, a second extension 1154, and a carriage 1156. The base 1152 includes a coupling 1155. The carriage 1156 includes a frame having a first rail 1150A and a second rail 1150B positioned on the side of the frame opposite the first rail 1150A. A first set of roller wheels 1159A are included on the first rail 1150A, and a second set of roller wheels 1159B are included on the second rail 1150B. A locking system is attached to the frame of the carriage 1156. The locking system includes a first locking bar 1165, a second locking bar 1166, a first locking motor 1158A, and a second locking motor 1158B. The locking bars 1165 and 1166 extend across the entire sides and below both sides of a carriage 1156 perpendicular to the first rail 1150 and the second rail 1150B. Each end of the locking bars 1165 and 1166 is attached to the rails 1150A and 1150B. According to the shown embodiment, the first locking motor 1158A is positioned below the central portion of the first rail 1150A. The second locking motor 1158B is positioned below the central portion of the second rail 1150B. The carriage 1156 also includes a pair of rails 1167 positioned above the upper side of the carriage 1156's frame. A pair of extensions 1153 and 1154 include a drive motor 1162, a first pair of drive belts 1163, and a second pair of drive belts 1164. The first extension 1153 is mounted in a movable engagement state with the base 1152. The second extension 1154 is mounted in a movable engagement state with the first extension 1153. The carriage 1156 is mounted in a movable engagement state with the second extension 1154.

[0069] The first extension 1153 includes a pair of upper and lower rails 1168. According to the shown embodiment, the pair of rails 1168 are formed as part of the frame of the second extension 1153. In various embodiments, the first extension 1153, the second extension 1154, and the carriage 1156 are nested together under the base 1152 when the bin handler 1122 is positioned within the tower robot 1161 and travels up and down within the elevator cell. The carriage 1156 and the second extension 1154 are attached to each other on a pair of rails 1167 provided on the carriage. The second extension 1154 is attached to the first extension 1152 on the lower rail included within a pair of upper and lower rails 1168. The first extension 1153 is attached to the base 1152 on the upper rail included within a pair of upper and lower rails 1168.

[0070] Figure 13 shows a bin handler 1122 configured to operate within a storage array containing several pairs of double-deep storage cells. Although the storage grid 1075 is not shown in Figure 13, the bin handler is shown in a fully extended position during operation, which may occur in the elevator row of the multi-level storage array system 1051. Specifically, the winch system 1120 of the tower robot 1161 was operated to lower the bin handler below the tower robot's frame 1124 to a selected height within the storage array. From that position, the bin handler may operate to extend its first extension 1153 and second extension 1154 from the base to move the carriage 1156 into a first storage cell positioned directly adjacent to the elevator row where the base 1152 is positioned. The bin handler 1152 may also operate by further extending the first extension 1153 and the second extension 1154 to move the carriage 1156 into the second storage cell positioned on the side of the first storage cell facing the base (i.e., positioning the carriage 1156 within the double deep cell of a pair of double deep cells).

[0071] The drive system for the extension of the bin handler 1122 includes a drive motor 1162, a first drive belt 1162, and a second drive belt 1164. According to one embodiment, the first pair of drive belts 1163 includes a series of teeth configured to engage with corresponding sets of teeth positioned below the base 1152. The second pair of drive belts 1164 includes a series of teeth configured to engage with corresponding sets of teeth positioned below the first extension 1153. In the shown embodiment, a single drive motor 1162 operates to spin the first pair of drive belts 1163 around the front and rear axles in the first extension 1153, while simultaneously spinning the second pair of drive belts 1164 around the front and rear axles in the second extension 1154. The engagement between several sets of teeth provides a mechanical force to extend the first extension from beneath the base 1152 as the drive belt 1163 rotates under the force of the drive motor. The engagement between several sets of teeth also provides a mechanical force to extend the second extension from beneath the first extension 1153 simultaneously as the drive belt 1164 rotates under the force of the drive motor. The first and second sets of roller wheels 1159A and 1159B engage on tracks contained within the storage array 1075 as the carriage 1154 extends into the first storage cell of the pair of double deep cells. This feature helps maintain the carriage in a horizontal position within the storage cell, even under the load of the storage bins. To reach the second cell of the pair of double deep cells, the drive motor 1162 operates to further spin the two pairs of drive belts 1163 and 1164. This results in further simultaneous distal horizontal movement (e.g., to a fully stretched position) of both the first stretch section 1163 and the second stretch section 1164. In an alternative embodiment, the two pairs of drive belts 1163 and 1164 are driven independently of each other so that one of the two stretch sections 1153 and 1154 is first stretched sequentially from one to the other.

[0072] The bin handler operates a locking system contained within the carriage 1156 as the carriage extends into the storage cell. Typically, the locking bars 1165 and 1166 grip the opposing edges of the storage bins to secure them to the carriage for transport by the tower robot 1161 within the multi-level storage array system 1051. With the carriage 1156 extending over a single-bay storage cell or over any storage cell in a pair of double-deep storage cells, the locking bars 1165 and 1166 are positioned over and directly adjacent to the opposing edges of the storage bins positioned within the cell. The operation of two locking motors 158A and 1158B moves the associated locking bars 1165 and 1166 into a secure engagement with each of the two opposing edges of the storage bin. With the storage bins securely held by the carriage 1156, the storage bins can be pulled into the elevator cell by the first extension 1153, the second extension 1154, and the carriage 1156, which are nested together beneath the base 1152. The tower robot 1161 now operates to raise and lower the bin handler 1122, including the storage bins, to a location where it will be transferred to the material transfer system at the base of the multi-level storage array system 1051, or alternatively, to leave the bin handler 1122 at another storage cell location accessible from the elevator row where it is positioned.

[0073] In various embodiments, the bin handler 1122 rotates 360 degrees around the vertical shaft of the bin handler. This allows the carriage 1156 to extend into a storage cell positioned above any of the four sides of the elevator cell in which the bin handler is positioned. Referring to Figure 14, a diagram of the bin handler assembly 1180 is shown. The bin handler assembly 1180 includes a bin handler 1122 and a trolley 1170 in which the bin handler 1122 is positioned. The trolley 1170 includes a frame 1171 and four wheel assemblies 1172A, 1172B, 1172C, and 1172D, one of which is positioned at each corner of the frame 1170. The trolley 1170 also houses a rotary drive assembly 1176.

[0074] Each wheel assembly 1172 includes a vertical frame 1173 and a pair of wheels, including a first wheel 1174A and a second wheel 1174B. According to the shown embodiment, the wheels 1174A and 1174B are positioned in a vertical orientation so that they can engage with the vertical frame of the storage array 1075 as the bin handler assembly 1180 travels up and down the elevator rows in the array. In this orientation, the wheels provide smooth vertical travel of the bin handler assembly 1180 at a fixed location in the center of the elevator rows.

[0075] According to some embodiments, the rotary drive assembly 1176 is configured to be attached to the coupling 1155 shown in Figure 13. The rotary drive system 1176 includes a motor that operates so that the bin handler 1122 below the trolley 1170 rotates 360 degrees around the vertical shaft of the bin handler assembly 1180.

[0076] The embodiments described above refer to a material exchange level employing a conveyor system, but other embodiments may include a shuttle system at this level. In these embodiments, the horizontal shuttle system is installed below a vertical storage cell row. According to one embodiment, the horizontal shuttle system includes a horizontal shuttle grid and one or more robotic platform shuttles. The shuttle grid is formed by a network of rails, or consists of multiple rail tiles installed in a grid arrangement or adjacent to one another. The rails include grooves that define the tracks of the wheels of the robotic platform shuttles to traverse. The robotic platform shuttles traverse the horizontal shuttle grid to be contained and / or deliver the storage bins to one of the robotic bin handlers.

[0077] The tower robot described above moves between locations along the upper level 1077 of the multi-level storage array system 1051 without carrying any load (i.e., without carrying the storage bins). However, in an alternative embodiment, the tower robot has the headroom necessary to pull the bins into the tower robot frame, and then moves between locations along the upper level 1077.

[0078] Referring here to Figure 15, plan views of a multilevel storage array system 1581 according to several embodiments are shown. In the embodiments shown, the system 1581 includes a framework 1582, a material transfer system 1583, and a plurality of mobile tower robots (e.g., mobile tower robot 1561). The framework 1582 includes vertical members 1584 and horizontal members 1585 fixed to each other to form a three-dimensional storage array including storage cells 1547 and elevator cells 1537. Here, a single elevator cell defined within a three-dimensional region positioned between dashed lines is uniquely identified as elevator cell 1537. However, elevator cells 1537 are positioned above each other to define a vertical elevator shaft 1586 within the entire multilevel storage array system 1581. A general contour of one elevator cell 1537 positioned within the storage array system 1581 is shown as a phantom for reference. The multi-level storage array system 1581 includes multiple storage bins 1565 employed for the temporary storage of materials in bins 1565 accessed via a tower robot. A single storage bin 1588 contained within the multiple storage bins 1565 is secured by the mobile tower robot 1561 shown in Figure 15.

[0079] In the illustrated embodiment, the material transfer system 1583 is positioned beneath a cell contained within the storage array system 1581. In various embodiments, the material transfer system 1583 includes a transport system configured to move storage bins from a drop-off station to locations under multiple vertical shafts for the storage and retrieval of material in individual storage bins; and from locations under multiple vertical shafts to a pickup station. The transport system may also move storage bins from a first elevator shaft location where they are retrieved and dropped off to a second elevator shaft location where they are raised back into the storage array and placed in a different storage cell (after being removed from the first storage cell). For example, if a storage bin contains material that is not selected for retrieval as frequently as expected, the storage bin may be moved to a less conspicuous location within the storage array (and vice versa).

[0080] Depending on the embodiment, the material transfer system 1583 may include one or more conveyor systems or shuttle systems (e.g., grid robots). In each method, the material transfer system 1583 operates to move the storage bins 1565 horizontally below the storage array. In some embodiments, the material transfer system 1583 is configured to move the storage bins up and down on an incline included within the system 1583. According to one embodiment, the material transfer system includes a combination of a conveyor system and a shuttle system. When a shuttle system is employed, the shuttle system may include a shuttle grid and one or more robot platform shuttles. The shuttle grid may be formed by a network of rails, or may consist of a grid arrangement or multiple rail tiles installed adjacent to each other. The rails include tracks for the wheels of the robot platform shuttles to traverse. Each movable tower robot 1561 includes a plurality of wheels 1528 (e.g., positioned on at least two opposing sides of the tower robot 1561). In one embodiment, the plurality of wheels 1528 are included on all four sides of the tower robot 1561. In another embodiment, the wheels may be positioned above the lowest part of the tower robot frame when not in use. In various embodiments, during the repositioning of the movable tower robot 1561 from a first location on the array of storage cells to a second location on the array of storage cells, the wheels 1528 are positioned at an altitude lower than the lowest altitude of the tower robot frame to allow the tower robot frame to clear the framework 1582 while the tower robot is in transition. Each movable tower robot 1561 also includes an electric drive system to provide power to the wheels 1528 for moving the tower robot between various locations on the storage array. For example, to move the tower robot 1561 from a first location on a first elevator shaft contained within a plurality of elevator shafts to a second location on a second elevator shaft contained within a plurality of elevator shafts, the first elevator shaft is a different elevator shaft from the second elevator shaft.

[0081] According to several embodiments, a lift system contained within the tower robot 1561 (e.g., a winch system 1120 shown and described with reference to Figure 11) is configured to move a bin handler assembly vertically within the elevator shaft to align the bin handler with a first set of storage cells positioned adjacent to the elevator shaft. Once positioned adjacent to the first set of storage cells, the bin handler is configured to move the first storage bin vertically within the first elevator shaft to retrieve the storage bin and release it to the transport system, thereby lowering the first storage bin to a transport system contained within the material transfer system 1583 for horizontal transport. According to these embodiments, the tower robot 1561 is configured to move on the storage array from a first position on the first elevator shaft to a second position on the second elevator shaft, and then to move the bin handler assembly vertically within the second elevator shaft to align the bin handler with a second set of storage cells positioned adjacent to the second elevator shaft, to search for the second storage bin, and to deliver the second storage bin to the transport system.

[0082] As described above in more detail with reference to the preceding figures, each mobile tower robot 1561 may include a winch system and a bin handler assembly. The bin handler is raised and lowered as needed to access bins adjacent to the elevator cell on which the bin handler is operating. Again, each mobile tower robot 1561 is in communication with a central control system that transmits data, including operation commands, to the mobile tower robot 1561. The operation commands provide the information necessary for the mobile tower robot 1561 to coordinate its activities within the multi-level storage array system 1581 and move the storage bins 1565 within the storage grid.

[0083] According to the demonstrated embodiment, the bin handler assembly contained within the mobile tower robot 1561 (see bin handler assembly 1180 shown and described with reference to Figure 14) is in the uppermost position. That is, the winch system lifted the bin handler assembly as far as possible within the frame of the mobile tower robot 1561. As described elsewhere in this specification, once the bin handler assembly, including the trolley and bin handler, is raised to the uppermost position, it is positioned within the frame of the mobile tower robots 1161 and 1561. That is, these elements are completely retracted into the tower robot frame (see, for example, Figure 11 and frame 1124). This allows the mobile tower robots 1161 and 1561 to be repositioned between various positions on the storage array as the frames of the tower robots 1161 and 1561 are raised above the upper level (e.g., upper level 1077) of the storage array on which the mobile tower robots 1161 and 1561 travel. As shown in Figure 15, the bottom of each wheel contained within the multiple wheels 1528 is lower than the lowest part of the frame. This works to raise the frame of the mobile tower robot and provide the clearance necessary for the tower robot to travel over the storage array.

[0084] However, in these embodiments, at least the lower portion of the bin 1588 is positioned below the frame and below the bottom of each wheel contained within the plurality of wheels 1528. Thus, in these embodiments, the movable tower robot 1561 cannot move laterally over the storage array when it possesses the bin, because the bin 1588 would collide with the framework 1582 (even by the bin handler assembly in a sufficiently raised position).

[0085] The applicants have found that prior limitations can be addressed with respect to a subset of locations within the multilevel storage array system 1581 by providing “high-speed travel lanes.” These high-speed lanes remove several horizontal elements within a pair of adjacent cells located at or near the top of the framework 1582 to provide linear (straight-line travel) areas between various elevator cells. According to these embodiments, the removal of selected horizontal elements provides travel paths that do not interfere with the travel of tower robots 1161 and 1561 that own bins (e.g., bin 1588). In practice, this technique may be employed for areas of the multilevel storage array system 1581 where storage cells that observe the maximum amount of bin handling or movement are located.

[0086] Bin (or tote) retrieval has been shown and described above with reference to a bin handler that includes an extender that moves into both the inner and outer storage cells for retrieving bins; however, other methods may be used according to other embodiments. For example, by a suitable mechanical interface, the bin handler may instead be coupled to the side of the storage bin adjacent to the elevator cell where the bin handler is positioned. In one embodiment, a suction attachment is employed. In another embodiment, the bin handler includes hardware for latching onto the near-side wall of the bin without the need to extend into the storage cell.

[0087] Having described several aspects of at least one embodiment of the present invention, it should be understood that various changes, modifications, and improvements will readily come to mind for those skilled in the art. Such changes, modifications, and improvements are intended to be part of this disclosure and to fall within the spirit and scope of the invention. Accordingly, the description and drawings set forth herein are for illustrative purposes only.

Claims

1. A storage system comprising a three-dimensional structure including an array of cells, wherein the array of cells is A first plurality of cells configured to hold individual storage bins for retrieval, wherein an array of the cells each forms a plurality of highly localized storage levels within the three-dimensional structure, and A second plurality of cells positioned relative to one another to form a plurality of vertical shafts located within the three-dimensional structure, wherein the plurality of vertical shafts are configured to allow access to storage cells contained within the first plurality of cells at each level of the plurality of storage levels, and the three-dimensional structure further comprises a second plurality of cells. A material transfer level positioned below the plurality of storage levels, wherein the material transfer level includes a transport system configured to move the individual storage bins a) from a drop-off station to a location below the plurality of vertical shafts, and b) from the location below the plurality of vertical shafts to a pickup station. The storage system further includes, In the storage system comprising a plurality of tower robots positioned on the three-dimensional structure, each of the plurality of tower robots comprising a vertical lift system including a bin handler, the plurality of tower robots configured to move the bin handler vertically within the plurality of vertical shafts to align the bin handler with the first plurality of cells at various heights, and each of the tower robots configured to move laterally on the three-dimensional structure between a plurality of different locations on the three-dimensional structure (including at least a first position positioned on a first vertical shaft included within the plurality of vertical shafts and a second position positioned on a second vertical shaft included within the plurality of vertical shafts), With the tower robot positioned at the first position, the vertical lift system is configured to position the bin handler within the first vertical shaft adjacent to a first set of storage cells at a selected altitude included in the various altitudes, the first set of storage cells comprising at least one inner cell configured to hold individual storage bins for later retrieval, the at least one inner cell comprising a first side positioned directly adjacent to the elevator cell, the first side from which the bin handler is positioned at the selected altitude, and a second side positioned opposite the first side. The bin handler, positioned adjacent to the first set of storage cells, is configured to retrieve the first storage bin located within the at least one inner cell for vertical transport from the selected altitude to the material transfer level (for the release of the first storage bin by the bin handler to the transport system), enabling the first storage bin to move from its location below the first vertical shaft. A storage system in which the tower robot is configured to move on the three-dimensional structure from the first position to the second position in order to access the second vertical shaft in order to search for the second storage bin and deliver the second storage bin to the transport system.

2. The storage system according to claim 1, wherein the transport system includes a conveyor system.

3. The storage system according to claim 2, wherein the conveyor system includes a plurality of electric conveyor tiles.

4. The storage system according to claim 1, wherein the drop-off station and the pickup station are located in the same place.

5. Each of the aforementioned tower robots is configured to raise and lower its associated bin handler between a sufficiently raised position and a sufficiently lowered position. Each of the plurality of tower robots includes a plurality of wheels configured to engage with the three-dimensional structure and propel the respective tower robot between the plurality of different locations on the three-dimensional structure. The storage system according to claim 1, wherein the lower portion of the storage bin extends under the plurality of wheels of each tower robot due to the associated bin handler in the sufficiently raised position and the storage bin firmly grasped by the associated bin handler.

6. Each of the aforementioned tower robots includes a winch assembly comprising a plurality of winches, and each of the plurality of winches includes a cable spool comprising a cable connected to the associated bin handler. The storage system according to claim 5, wherein each of the plurality of tower robots includes an actuator for automatically raising and lowering the winch assembly as it moves between the sufficiently lowered position and the sufficiently raised position to assist the associated bin handler in winding the cable around the cable spool.

7. The storage system according to claim 1, wherein the transport system includes a shuttle system configured to move the individual storage bins on the material transfer level.

8. The storage system according to claim 7, wherein the shuttle system comprises a horizontal shuttle grid and one or more robotic platform shuttles configured to traverse the horizontal shuttle grid to accommodate the individual storage bins from the bin handler.

9. The three-dimensional structure further includes a frame having vertical members that define the plurality of vertical shafts, The storage system according to claim 1, wherein the bin handler is contained within a bin handler assembly including the bin handler and a trolley, and the bin handler is coupled to the bin handler assembly below the trolley.

10. The storage system according to claim 9, wherein the trolley includes a plurality of guide wheel assemblies configured to engage the vertical member of one selected vertical shaft of the plurality of vertical shafts with the bin handler assembly lowered within one selected vertical shaft of the plurality of vertical shafts.

11. The aforementioned set of storage cells includes at least one set of double-deep storage cells, which include at least one inner cell and an outer cell. The outer cell contained within the at least one pair of double deep storage cells is positioned adjacent to the second side of the at least one inner cell. The storage system according to claim 1, wherein the bin handler positioned adjacent to the set of storage cells is configured to retrieve the storage bins positioned within the outer cells for the vertical transport from the selected altitude to the material transfer level.

12. The at least one inner cell is one of a plurality of inner cells contained within the set of storage cells, The aforementioned outer cell is one of a plurality of outer cells contained within the set of storage cells, The storage system according to claim 11, wherein each set of storage cells comprises a plurality of sets of double deep storage cells, each of which comprises a) one of the plurality of inner cells, each having a first side positioned directly adjacent to the elevator cell, where the bin handler is positioned at the selected height and opposite to the respective first side; and b) one of the plurality of outer cells, each of which is positioned adjacent to the respective second side of the respective inner cell contained within each set of double deep storage cells.

13. The bin handler includes a base and a plurality of nested extensions. The storage system according to claim 11, wherein the extension is coupled to at least one motor employed to move the extension between a retracted position below the base and a plurality of extension positions, the plurality of extension positions including a first extension position in which the bin handler is positioned to firmly grasp a first storage bin positioned in the at least one inner cell, and a second extension position in which the bin handler is positioned to penetrate the at least one inner cell to reach and firmly grasp a second storage bin positioned in the outer cell when empty.

14. A method for storing and retrieving materials, wherein the method is: To provide a plurality of storage cells arranged together at various heights within a three-dimensional structure, wherein the plurality of storage cells are configured to hold individual storage bins for retrieval. The three-dimensional structure includes a plurality of elevator cells positioned relative to each other to form a plurality of vertical shafts, wherein the plurality of vertical shafts are configured to allow access to the storage cells contained within the plurality of storage cells at each of the various altitudes. Positioning a material transfer level beneath the plurality of storage cells and the plurality of elevator cells, wherein the material transfer level includes a transport system configured to move the individual storage bins a) from a drop-off station to a location beneath the plurality of vertical shafts, and b) from the location beneath the plurality of vertical shafts to a pickup station for storage and retrieval of the material in the individual storage bins. Positioning a plurality of tower robots on the three-dimensional structure, each of the plurality of tower robots including a vertical lift system including a bin handler, the plurality of tower robots configured to move the bin handler vertically within the plurality of vertical shafts to align the bin handler with the plurality of storage cells at various altitudes, and each of the tower robots configured to move laterally on the three-dimensional structure between a plurality of different locations on the three-dimensional structure (including at least a first position positioned on a first vertical shaft included within the plurality of vertical shafts and a second position positioned on a second vertical shaft included within the plurality of vertical shafts), The vertical lift system is configured such that the bin handler is positioned within the first vertical shaft adjacent to a first set of storage cells at a selected altitude included in the various altitudes, wherein the bin handler positioned adjacent to the first set of storage cells is positioned to retrieve the first storage bin located within the first set of storage cells for vertical transport from the selected altitude to the material transfer level (for the release of the first storage bin by the bin handler to the transport system), enabling the first storage bin to move from its location below the first vertical shaft, and A method comprising configuring the tower robot to move on the three-dimensional structure from the first position to the second position in order to access the second vertical shaft in order to search for the second storage bin and deliver the second storage bin to the transport system.

15. The material storage and retrieval method according to claim 14, further comprising including a conveyor system within the transport system which includes a plurality of electric conveyor tiles.

16. A method for material storage and retrieval according to claim 14, further comprising including a shuttle system configured to move the individual storage bins on the material transfer level, wherein the shuttle system includes a plurality of shuttles configured to traverse a horizontal shuttle grid to receive the individual storage bins from the bin handler.

17. A tower robot employed in conjunction with a storage array including multiple elevator shafts positioned above a transport system, wherein the tower robot Frame, A lift system fixed to the aforementioned frame, A bin handler assembly coupled to a vertical lift system, comprising a trolley and a bin handler coupled to the bin handler assembly below the trolley, A set of wheels extending below the frame, and A drive system configured to rotate a set of wheels in order to move the tower robot from a first position on a first elevator shaft included in the plurality of elevator shafts to a second position on a second elevator shaft included in the plurality of elevator shafts, wherein the first elevator shaft is a different elevator shaft from the second elevator shaft, the drive system includes The lift system is configured to move the bin handler assembly vertically within the first elevator shaft in order to align the bin handler with a first set of storage cells positioned adjacent to the first elevator shaft. The bin handler, positioned adjacent to the first set of storage cells, is configured to operate to retrieve the first storage bin in order to lower the first storage bin to the transport system for horizontal transport and to release the first storage bin to the transport system, and to move the first storage bin vertically within the first elevator shaft. The tower robot is configured to move from a first position to a second position on the storage array in order to locate a second storage bin and deliver the second storage bin to the transport system, and then to move the bin handler assembly vertically within the second elevator shaft in order to align the bin handler with a second set of storage cells positioned adjacent to the second elevator shaft.

18. The tower robot according to claim 17, wherein the bin handler positioned in a selected elevator shaft adjacent to a selected set of storage cells positioned at a selected altitude in the storage array is configured to lower the selected storage bin to the transport system for horizontal transport so as to extend laterally to a storage cell contained within the selected set of storage cells in the storage array in order to retrieve the selected storage bin, and to release the selected storage bin to the transport system so as to move into the selected elevator shaft contained within the plurality of elevator shafts.

19. The selected set of storage cells includes at least one inner cell configured to hold individual storage bins for later retrieval, the at least one inner cell including a first edge positioned directly adjacent to the elevator cell and the first edge on which the bin handler is positioned at the selected height, and a second edge positioned opposite the first edge. The selected set of storage cells includes at least one set of double deep storage cells, which include at least one inner cell and an outer cell. The outer cell contained within the at least one pair of double deep storage cells is positioned adjacent to the second side of the at least one inner cell. The tower robot according to claim 18, wherein the bin handler positioned adjacent to the selected set of storage cells is configured to retrieve the storage bins positioned within the outer cells for vertical transport from the selected altitude to the transport system.

20. The tower robot according to claim 18, wherein the tower robot includes a vertical axis, and the bin handler includes a rotary drive system coupled to the bin handler, the rotary drive system configured to rotate the bin handler 360 degrees about the vertical axis below the trolley in the plurality of elevator shafts.

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