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

Abstract

Systems and methods relating to a mobile area in an automated storage and retrieval system are provided. In one embodiment, the system may include a storage structure including a storage location and a path traversed by a mobile robot to access the storage location. The system may also include a mobile area adjacent to the storage structure and providing access to the mobile robot. The mobile area may include a frame portion formed by beams for connecting to the storage structure and a floor supported by the frame portion. The floor may include a panel having at least one panel which may include guidelines at predetermined locations to facilitate the movement of the mobile robot on it. Panels and methods for construction are also provided.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the benefit and priority of U.S. Provisional Application No. 63 / 472,885, filed on June 14, 2023, the entire disclosure of which is incorporated herein by reference.

[0002] [Technical Field] The present invention generally relates to automated storage and retrieval systems for storing goods, and more specifically, to modular moving areas for the navigation and movement of mobile robots.

Background Art

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

[0004] Areas are needed where mobile robots can navigate and access different aisles. To enable mobile robots to access different aisles and different areas of a storage structure and facility, an in - rack transfer plane (IRTP), or moving area or support deck, may be desirable. It may be desirable to result in the manufacture and assembly of a support deck with modular configurable pre - fabricated panels that can help support and guide the robot.

Summary of the Invention

[0005] This specification discloses embodiments of systems, apparatus, and methods including moving areas and moving panels, such as those that may be used in automated storage and retrieval systems. This description includes the following drawings. [Brief explanation of the drawing]

[0006] [Figure 1] This is a perspective view of an automated storage and retrieval system in several embodiments. [Figure 2] Figure 1 shows a partial perspective view of an automated storage and retrieval system according to several embodiments. [Figure 3] Figure 1 shows a partial perspective view of an automated storage and retrieval system according to several embodiments. [Figure 4] Figure 1 shows a partial perspective view of an automated storage and retrieval system according to several embodiments. [Figure 5] This is a perspective view of the moving region according to several embodiments. [Figure 6] Figure 5 is a perspective view of the moving region according to several embodiments. [Figure 7] Figure 5 is a perspective view of the moving region according to several embodiments. [Figure 8] This is a partial perspective view of the moving region in Figure 5 according to several embodiments. [Figure 9] This is a top view of a panel according to several embodiments. [Figure 10] This is a schematic diagram of the panel shown in Figure 9 according to several embodiments. [Figure 11] This is a partial top view of a panel in a moving region according to several embodiments. [Figure 12] This is a partial perspective view of the panel in the moving region shown in Figure 11, according to several embodiments. [Figure 13] This is a partial perspective view of the panel in the moving region shown in Figure 11, according to several embodiments. [Figure 14] This is a flowchart showing several embodiments.

[0007] Elements in the drawings are illustrative for brevity and clarity and are not necessarily drawn to scale. For example, to aid in understanding the various embodiments of the invention, the dimensions and / or relative positions of some elements in the drawings may be emphasized relative to others. Also, to encourage less limitation on the view of the various embodiments of the invention, common but well-understood elements that are useful or necessary in commercially viable embodiments are often not illustrated. Certain actions and / or processes may be described or depicted in a particular order of occurrence, but those skilled in the art will understand that such specificity regarding order is not actually necessary. Terms and expressions used herein have the ordinary technical meanings given to such terms and expressions by those skilled in the art specified above, unless otherwise specified herein. [Modes for carrying out the invention]

[0008] The following description should not be interpreted restrictively, but is provided solely for the purpose of illustrating the general principles of exemplary embodiments. Throughout this specification, references to “one form,” “one embodiment,” “embodiment,” “several embodiments,” “implementation,” “several implementations,” “several applications,” or similar terms mean that certain features, structures, or characteristics described in relation to an embodiment are included in at least one embodiment of this disclosure. Thus, throughout this specification, when phrases such as “in one embodiment,” “in an embodiment,” “in some embodiments,” “in some implementations,” and similar terms appear, they do not all refer to the same embodiment.

[0009] The terms “upper” and “lower,” “upper side” and “lower side,” “vertical” and “horizontal,” as used herein, are illustrative and for illustrative purposes only, and are not intended to limit the description of embodiments insofar as the position and orientation of the referenced article are interchangeable. Furthermore, as used herein, the terms “substantially” and / or “about” mean that the specified dimensions or parameters may be modified within acceptable manufacturing tolerances for a given application.

[0010] Generally speaking, this specification provides systems, apparatus and methods for automated storage and retrieval systems according to various embodiments. In one embodiment, the system includes a first storage structure comprising a plurality of storage locations configured to store totes containing goods, wherein the first storage structure includes a plurality of first paths, each storage location being accessible by the paths, the paths being configured to be traversed by a plurality of mobile robots, each mobile robot being configured to access a storage location and place or retrieve a tote in the storage location; and a mobile area adjacent to the first storage structure, providing mobile robots with access to enter and exit at least a portion of the paths, wherein the mobile area includes a frame portion formed of a plurality of beams configured to connect to the first storage structure; and a floor supported by the frame portion, the floor comprising a plurality of panels collectively defining the floor, at least one panel including one or more guidelines at a given location on at least one panel for facilitating the movement of mobile robots thereon.

[0011] In some implementations, the system includes one or more guidelines, which include one or more magnetic guidelines, and at least one panel further includes at least one groove configured to receive press-fit fitting metal material to form one or more magnetic guidelines. In some implementations, at least one mobile robot includes a magnetic sensor to detect one or more magnetic guidelines to facilitate the movement of at least one mobile robot on at least one panel. In some implementations, at least one panel further includes an alignment feature configured to align one or more guidelines in a predetermined manner with respect to a corresponding path, the corresponding path configured for the mobile robot to enter and exit between the corresponding path and at least one panel. In some implementations, the alignment feature includes at least two mounting holes at predetermined locations on at least one panel, each of the at least two mounting holes configured to receive a fastener. In some implementations, at least one panel includes at least one reference marker applied to the top surface of at least one panel, the at least one reference marker configured to facilitate position determination and navigation by the mobile robot. In some implementations, at least one panel includes at least one radio frequency identification (RFID) tag applied to the bottom surface of at least one panel, the at least one RFID tag being configured to facilitate position determination and navigation by a mobile robot. In some implementations, the system further includes a transition plate positioned between one of the at least one panels and a corresponding path, the transition plate being configured to connect to an alignment feature of one panel for alignment between the transition plate and one panel, and between the transition plate and the corresponding path. In some implementations, the system further includes a first plurality of mounting brackets, each mounting bracket connecting a first end of each beam to a corresponding end of a first storage structure.In some implementations, the system further includes a second storage structure comprising a plurality of storage spaces configured to store totes for storing goods, wherein the second storage structure comprises a plurality of second paths, and each storage space is accessible by the paths; and a plurality of second mounting brackets, wherein each mounting bracket connects a second end of each beam to a corresponding end of the second storage structure.

[0012] In another embodiment, a mobile area for an automated storage and retrieval system is provided, the mobile area comprising: a frame portion formed of a plurality of beams configured to connect to a first storage structure, the first storage structure including a plurality of storage locations configured to store totes containing goods, the first storage structure including a plurality of first paths, each storage location being accessible by the paths, the paths being configured to be traversed by a plurality of mobile robots, each mobile robot being configured to access a storage location and place or retrieve a tote in the storage location; and a floor supported by the frame portion, the floor comprising a plurality of panels, at least one of which has one or more guidelines to facilitate the movement of mobile robots thereon.

[0013] In another embodiment, a panel is provided for supporting a mobile robot moving on the panel, the panel including one or more magnetic guidelines formed at predetermined locations on the upper surface of the panel to facilitate the movement of the mobile robot along the upper surface; at least one groove formed on the upper surface of the panel, the at least one groove configured to receive a metallic material to form one or more magnetic guidelines; and an alignment feature configured to align one or more magnetic guidelines in a predetermined manner with respect to a corresponding path, the corresponding path configured for the mobile robot to enter and exit between the corresponding path and the panel. The panel may also include some or all of the other features discussed above.

[0014] In yet another form, a method is provided for constructing an automated storage and retrieval system, the method comprising the steps of: providing a storage structure comprising a plurality of storage locations configured to store totes containing goods, wherein the storage structure comprises a plurality of paths, each storage location being accessible by the paths, the paths being configured to be traversed by a plurality of mobile robots, and each mobile robot being configured to access a storage location and place or retrieve a tote in the storage location; connecting a frame portion of a mobile area to the storage structure by connecting a plurality of beams to the storage structure, the mobile area enabling mobile robots to enter and exit the paths; and installing a floor supported by the frame portion, the floor being formed by a plurality of panels collectively defining the floor, at least one panel including one or more guidelines at a given location on at least one panel for facilitating the movement of a mobile robot thereon.

[0015] In some implementations, the method may further include receiving at least one panel having at least one groove pre-formed for receiving press-fit metal material to form one or more guidelines before floor installation. In some implementations, the method may further include applying at least one reference marker to at least one panel after floor installation, wherein the at least one reference marker is configured to facilitate position determination and navigation by a mobile robot moving on the floor. In some implementations, the method may further include applying at least one RFID tag to at least one panel after floor installation, wherein the at least one RFID tag is configured to facilitate position determination and navigation by a mobile robot moving on the floor. In some implementations, the method may further include receiving at least one panel having alignment features for aligning one or more guidelines to a corresponding path in a predetermined manner, wherein the corresponding path is configured for a mobile robot to enter and exit between the corresponding path and at least one panel. In some implementations, the alignment feature includes at least two mounting holes at a given location on at least one panel, and each of the at least two mounting holes is configured to receive a fastener.

[0016] In one aspect, without limitation, the present disclosure is generally directed to reducing excessive labor and time in the installation of a moving area connected to a storage structure. This moving area can generally be configured to be usable by a mobile robot that retrieves totes of merchandise stored in a specific storage location within an adjacent storage structure that is part of an automated storage and retrieval system. This moving area can enable the robot to access different areas of the automated storage and retrieval system from the storage structure. The robot can use various features for navigation and position recognition, but these may need to be created at great cost and risk within a custom build. Typically, the construction of the moving area can be done on-site and can involve multiple layers of installation procedures that can cause multiple errors. The installation procedures can include the construction of a frame and a floor setting, followed by the construction of navigation features and posts for maneuvering the robot.

[0017] In one aspect, without limitation, the present disclosure utilizes the manufacturing of modular components in a factory setting using prefabricated panels (or tiles) that can be assembled efficiently and with low risk. Further, the present disclosure results in the manufacturing of guidelines on the panel surface for the movement of the robot. Additional features may be incorporated on the panel surface for the position recognition of the robot. This innovation enables a modular and scalable construction of the moving area, thereby reducing costs and eliminating assembly risks. It also reduces the amount of manufacturing work on-site.

[0018] Figures 1 and 2 show diagrams of an automated storage and retrieval system 100. In one form, this system 100 can be incorporated wholly or in part into an order fulfillment facility. The system 100 can include one or more storage structures 102 having a number of storage locations 104. Each storage structure 102 can include a y-z arrangement of horizontally aligned storage locations and vertically changing levels of a vertical tower. The mobile robot 108 can move between storage levels in the z-direction within a tower having changing levels. The storage structure 102 can form a pair of storage bays 110 that are arranged opposite each other and separated by a path 112. In one form, the path 112 can be in the form of a passageway, and the passageway 112 can have a width such that a mobile robot 108 moving within the passageway 112 can transfer a container to (or retrieve a container from) a storage bay 110 on either side of the passageway 112. Generally, the mobile robot 108 is assumed to be able to transport totes of merchandise from storage locations 104 to several designated areas for picking up the merchandise. In some forms, the mobile robot 108 can also carry a tote for containing merchandise that is returned to the storage structure 102.

[0019] Figures 1 and 2 show an example of a movement area 114, i.e., an In-Rack Transfer Plane (IRTP), which will be discussed in more detail below. The movement area 114 can be positioned at different vertical levels between storage structures 102. The movement area 114 enables the mobile robot 108 to access different passageways of the storage structure 102, access different storage structures, or access other areas of the system or facility.

[0020] As described above, the automated storage and retrieval system 100 may utilize several mobile robots 108 to transport totes or other product or order containers to and from storage locations 104. The term “tote” broadly refers to any type of container that can be used to hold goods. The mobile robots 108 may be self-guided and / or rail-guided to move horizontally and vertically within aisles 112 to transport totes or other product containers between the mobile robots 108 and storage locations 104. The mobile robots 108 may have access to storage shelves on either side of aisles 112 in the x-direction at a given level. As mentioned, the system 100 may also include a vertical tower with varying levels, in which the mobile robots 108 may move vertically in the z-direction between levels in storage locations 104.

[0021] Further details of storage structures, mobile robots, and various other embodiments of automated storage and retrieval systems that may be used are described, for example, in the following U.S. patents and patent applications: U.S. Patent No. 9,139,363, U.S. Patent No. 10,435,241, U.S. Patent No. 11,142,398, U.S. Patent No. 10,984,375, U.S. Patent No. 10,952,533, U.S. Patent No. 11,267,651, U.S. Patent Application No. 63 / 127,762, and U.S. Patent Application No. 17 / 957,266. Each of these patents and applications is incorporated herein by reference in whole.

[0022] Figure 3 shows a portion of the automated storage and retrieval system 100 with a portion of the storage structure removed for clarity. Figure 3 shows three stacked mobile areas 114 located at different vertical levels, i.e., between and connecting two storage structures 102A and 102B. As will be further described below, each mobile area 114 is generally in the form of a panel floor supported by a beam frame. The ends of each mobile area 114 are attached to the corresponding ends of each storage structure 102A and 102B to the support columns 116. In one embodiment, a mobile robot 108 is assumed to retrieve totes containing goods from storage locations 104 within each storage structure 102A and 102B. The movement area 114 allows the mobile robot 108, exiting the storage structure 102A through passage 112, to change direction and enter a different passage 112 within the same storage structure 102A, or to orient itself to enter a selected passage 112 within the second storage structure 102B, or to move to a different area within the automated storage and retrieval system 100 (such as a designated order pickup area).

[0023] Figure 4 shows another part of the automated storage and retrieval system 100 with a portion of the storage structure removed for clarity. Figure 4 shows two mobile areas 114 at different vertical levels adjacent to the storage structure 102. One end of each mobile area 114 is attached to a support column 116 at the corresponding end of the storage structure 102. The other end of each mobile area 114 is attached to another support column 116. The mobile areas 114 allow a mobile robot 108 exiting the passage 112 from the storage structure 102 to change direction and enter a different passage 112 within the same storage structure 102A, or to move to a different area within the automated storage and retrieval system 100 (such as a designated order pickup area).

[0024] Accordingly, in some embodiments, the automated storage and retrieval system 100 includes one or more storage structures 102 and a plurality of mobile robots 108. In one embodiment, the system 100 may include a first storage structure 102A that includes a plurality of storage locations 104 configured to store totes containing goods. The first storage structure 102A may include a plurality of passages 112, through which each storage location 104 is accessible. The system 100 may also include a plurality of mobile robots 108 configured to travel through the plurality of passages 112 of the first storage structure 102A. Each mobile robot 108 may be configured to access the storage locations 104 and place or retrieve totes from the storage locations 104. The system 100 may also include a second storage structure 102B that includes a plurality of storage locations 104 configured to store totes containing goods, the second storage structure 102B includes a plurality of passages 112, through which each storage location 104 is accessible.

[0025] Referring to Figure 5, a partially assembled mobile area 114 is shown. The drawing shows only the support ends of one or more storage structures 102. The mobile area 114 includes a frame section 118 and a floor 120. The frame section 118 includes several beams 122 that are attached to one or more storage structures 102. In the example of Figure 3, two ends of the beams are attached to the corresponding ends of storage structures 102A and 102B. In the example of Figure 4, one end of the beam is attached to the corresponding end of storage structure 102, while the other end of the beam is attached to a support column 116. Thus, the beams 122 of the frame section 118 support the floor 120.

[0026] Figures 6 and 7 show the assembled mobile area 114. In one embodiment, the mobile area 114 may consist of two types of panels: mobile panels 124 and connecting panels 126. In the drawings, in this particular example, there are four mobile panels 124. Each mobile panel 124 may include guidelines 128 extending along two centerlines of each mobile panel 124, thereby dividing each mobile panel 124 into four sections. These guidelines 128 enable guided movement by the mobile robot 108 along these centerlines, as will be further described below. The connecting panel 126 extends in a central strip between two sets of mobile panels 124. In this embodiment, panels 124 and 126 are fastened to each other by cleats 130, as also shown in Figure 8. These cleats 130 are optional, and in another embodiment, alternative fasteners may be used. Furthermore, as shown in Figure 7, a transition plate 132 may be provided to connect the passage 112 within the storage structure 102 to the guideline 128 of the panel 124 and align them. This transition plate 132 will be described in more detail below.

[0027] Therefore, in some forms, the system 100 may include a mobile area 114 adjacent to the first storage structure 102A, providing a mobile robot 108 with access to enter and exit the passage 112 of the storage structure 102. The mobile area 114 may include a frame portion 118 formed of a plurality of beams 122 configured for attachment to the first storage structure 102A. Furthermore, the system 100 may include a floor 120 supported by the frame portion 118, the floor 120 being formed of a plurality of panels collectively defining the floor 120. The floor 120 may include at least one panel 124 having one or more guidelines 128 at predetermined locations on the panel 124 to facilitate the movement of the mobile robot 108 over it.

[0028] Referring to Figure 9, a top view of panel 200 is shown. In one embodiment, panel 200 having the features described below is envisioned to be used in general in the mobile area 114 and the automated storage and retrieval system 100. These may be prefabricated in whole or in part and may be used modularly on the floor of the mobile area 114. In another embodiment, panel 200 is also envisioned to be used in other situations where it is desirable to provide a surface for the movement and navigation of a mobile robot.

[0029] Panel 200 may be roughly rectangular in shape and may include two guidelines 202 formed roughly along the horizontal and vertical centerlines of panel 200. In this configuration, the robot may move along one of the centerlines and then, at or approaching the intersection of the two centerlines, may move in a straight line or change direction. Although the guidelines 202 are shown to be formed along the horizontal and vertical centerlines of panel 200, it is also envisioned that other forms of guidelines may be used. For example, the guidelines 202 may be positioned at some predetermined non-perpendicular angle to the edges of the panel. Furthermore, it is also envisioned that the guidelines may take the form of a spaced pattern at predetermined locations on panel 200 that the robot can detect and use for navigation. Other robot guides are also available.

[0030] In one embodiment, the guideline 202 may be a magnetic guideline, and at least one groove is configured to receive a press-fit metal material to form one or more magnetic guidelines 202. In this embodiment, the magnetic guideline 202 may be created by pressing a magnetic material into a groove designed to capture a line in a press-fit without the need for adhesive. It is also envisioned that these magnetic guidelines 202 may be prefabricated elsewhere by the panel manufacturer before being shipped and installed to form the floor 120 of the moving area 114. In one embodiment, the panel may be partially formed of a resin material.

[0031] Referring to Figure 10, a schematic side view of panel 200 is shown in which a mobile robot 108 moves over panel 200. As can be seen, panel 200 includes magnetic guidelines 202 formed on the upper surface of panel 200. In one embodiment, it is assumed that the mobile robot 108 may include a magnetic sensor 109 that detects one or more magnetic guidelines 202 to facilitate the movement of the mobile robot 108 over panel 200. This magnetic sensor 109 may be a Hall effect sensor and may be located on the bottom of the mobile robot 108. In some situations, it may be desirable to use magnetic guidelines 202 rather than painted guidelines. Painted guidelines may tend to wear off over time and may not be detected by the mobile robot 108's optical sensors under certain conditions, such as when the mobile robot 108 moves in and out of a temperature-controlled environment. In these situations, the optical sensors used to follow painted lines may become cloudy and stop working.

[0032] Figure 9 also shows alignment features for aligning the panel 200 to a specific orientation, such as during installation in the moving area 114. In one embodiment, the panel 200 may include alignment features for aligning magnetic guidelines 202 in a predetermined manner with respect to a corresponding passage 112, the corresponding passage 112 being configured to allow a mobile robot 108 to exit from the passage 112 to the panel 200. These alignment features may include at least two mounting holes 208 at predetermined locations on the panel 200, each of which is configured to receive fasteners. As can be seen, in one embodiment, these mounting holes 208 may be located near the edges of the panel 200 corresponding to the long sides of a rectangle. These mounting holes 208 receive fasteners that secure the panel 200 to the beam 122 below.

[0033] In one embodiment, these mounting holes 208 align the magnetic guideline 202 with the corresponding passage. In other words, in one embodiment, the mounting holes 208 make it possible to precisely position the magnetic guideline 202 of the panel 200 at the center of the passage centerline of the storage structure 102. Furthermore, this alignment feature can be used to make installation easier and reduce installation errors by allowing the panel 200 to be installed in only a specific orientation. For example, as shown in Figure 9, the mounting holes 208 may be arranged so that the panel 200 can be installed in only one of two orientations, i.e., with its long side parallel to the end of the storage structure 102. In other words, there may be two sets of mounting holes 208, each set located adjacent to the edge of the long side, thereby allowing the panel 200 to be installed in one of two orientations. This arrangement of mounting holes is asymmetrical in that it is not possible to install the panel 200 in the other two orientations, thereby reducing installation errors. Alternatively, as another example, the mounting holes 208 may be arranged so that the panel 200 can be installed in exactly one orientation. In one embodiment, it is also envisioned that these mounting holes 208 may be formed elsewhere by the panel manufacturer before being shipped and installed to form the floor 120 of the moving area 114.

[0034] Figure 9 also shows two sets of fastening holes 210 arranged parallel to each other. In some embodiments, these two sets of fastening holes 210 are also envisioned to be used as a substitute for the cleats 130 described above. This pattern of fastening holes 210 may allow the panel 200 to be fastened to the beam 122 using standard self-tapping screws. Again, in one embodiment, these fastening holes 210 are also envisioned to be formed by the panel manufacturer before installation.

[0035] Panel 200 may include features to assist navigation by the mobile robot 108. For example, panel 200 may include at least one reference marker 212 applied to the upper surface of panel 200. As shown in Figure 9, in one embodiment, two reference markers 212 may be formed near the center of panel 200. In this embodiment, the two reference markers 212 are positioned in an oblique orientation with respect to the horizontal magnetic guideline 202 and the vertical magnetic guideline 202. Furthermore, in this embodiment, they are in opposing quadrants on the opposite side of panel 200, as defined by the horizontal magnetic guideline 202 and the vertical magnetic guideline 202, and are generally symmetrical with respect to the center. This symmetrical arrangement makes it possible to install panel 200 in one of two orientations (one orientation being 180 degrees to the other).

[0036] In one embodiment, it is assumed that grooves can be cut into the panel 200 during its prefabrication and before its installation. After the panel is installed, reference markers in the form of reference magnets can be placed in these grooves. In other words, the reference markers 212 can be applied or formed after the panel 200 is installed.

[0037] These reference markers 212 can be used as reference points to enable the mobile robot 108 to locate its position and assist in navigation. Generally, these reference points are assumed to be detectable by the mobile robot 108's imaging sensors. In other words, the reference markers 212 are configured to facilitate position determination and navigation by the mobile robot moving on the floor 120 of the mobile area 114. While an example of reference marker type and arrangement is shown, it should be understood that other types and arrangements may be used.

[0038] Another feature that can be used as a navigation aid is an RFID tag 214. The RFID tag 214 can be used in addition to, or as a substitute for, the reference marker 212. For example, as shown in Figure 9, the top surface of the panel 200 includes markings 213 for drilling holes for the installation of (one or more) RFID tags 214. These markings may be arranged symmetrically with respect to the center of the panel 200 so as to allow the panel 200 to be installed in one of two orientations. Furthermore, in one embodiment, these markings are applied during the prefabrication of the panel 200.

[0039] Furthermore, as shown in Figure 10, it is assumed that the RFID tags 214 can generally be applied to the bottom surface, or underside, of the panel 200. In one embodiment, holes are drilled through the panel 200 to allow the RFID tags 214 to be applied to the bottom surface after the panel 200 has been installed. The panel 200 may include at least one RFID tag 214 applied to the bottom surface of the panel 200. The RFID tags 214 are configured to facilitate position determination and navigation by a mobile robot moving on the floor 120.

[0040] As described above, the automated storage and retrieval system 100 may include a transition plate 132. Figure 11 is a partial top view of a panel 200 connected to the transition plate 132, and Figure 12 is a partial perspective view of the panel 200 connected to the transition plate 132. In one embodiment, the transition plate 132 is located midway between the panel 200 and the corresponding passage 112 of the storage structure 102. In one embodiment, the magnetic guideline 202 of the panel 200 is intended to be aligned with the centerline of the corresponding passage 112. In one embodiment, it is assumed that a mobile robot 108 can be self-guided and / or rail-guided along the centerline of the passage 112 of the storage structure 102.

[0041] As shown in Figure 11, the transition plate 132 is mounted to the mounting holes 208 of the panel 200 and configured to align the transition plate 132 with both the panel 200 and the corresponding passage 112. It includes two tabs or extensions 133 with through holes to allow the transition plate 132 to be mounted to and aligned with the mounting holes 208 of the panel 200. In one embodiment, the transition plate 132 allows the mobile robot 108 to travel from the storage structure 102 to the movement area 114 across a smooth, coplanar plane. This can also function as a transition between the slightly different heights of the passage 112 in the storage structure 102 and the panel 200 in the movement area 114. Furthermore, it shares the same mounting holes 208 as the panel 200, thereby sharing alignment features with the panel 200. Furthermore, as shown in Figure 11, in one embodiment it can be mounted between two beams 122 and two supports 116.

[0042] The automated storage and retrieval system 100 may also include mounting brackets 134. Figure 13 is a partial view showing mounting brackets 134 connecting beams 122 to columns 116 at one end of a storage structure 102. In one embodiment, each mounting bracket 134 connects the first end of each beam 122 to the corresponding end of the storage structure 102. Mounting brackets 134 may be used at both ends of a beam 122 so that the beam is attached to a first storage structure 102A at one end and the beam 122 is attached to a second storage structure 102B at the other end. Furthermore, in one embodiment, beams 122 forming a frame section 118 are connected to the support structure 102, while panels 200 forming a floor 120 are connected to the beams 122. In general, the mounting brackets 134 make it possible to use standardized beams 122 of the same size and characteristics universally across various moving area assemblies. As can be seen, Figure 13 shows two types of mounting brackets 134A and 134B that may be used, but other types of brackets may be used. In one embodiment, the two types of mounting brackets 134A and 134B are attached to different structures of the column 116, thereby establishing the desired load-bearing assembly.

[0043] Figure 14 shows process 300 for constructing an automated storage and retrieval system. Generally, process 300 is assumed to include some or all of the components of automated storage and retrieval system 100 and some or all of the features of panel 200. The above descriptions of system 100 and panel 200 are generally incorporated here.

[0044] Block 302 provides a storage structure having storage spaces for storing totes that contain goods. Generally, the storage structure may include multiple pathways in the form of aisles, and it is assumed that each storage space is accessible by an aisle. In one embodiment, it is assumed that the storage structure is constructed before the construction of a mobile area adjacent to the storage structure.

[0045] In block 304, a mobile robot may be used, configured to travel through the aisles of the storage structure. The mobile robot is configured to access the storage area and place or retrieve totes within the storage area. Generally, it is assumed that the mobile robot may be provided at any time during process 300. For example, the mobile robot may be provided after the construction of both the storage structure and the mobile area is complete.

[0046] In block 306, one or more prefabricated panels are received, each having magnetic guidelines and alignment features. In one embodiment, it is assumed that a panel having several prefabricated features is received before the panel is installed. The panel may have at least one groove pre-formed to receive press-fitting metal material to form one or more magnetic guidelines before installation on the floor. The panel may also include alignment features that align one or more magnetic guidelines in a predetermined manner with respect to a corresponding passage, the corresponding passage being configured to allow a mobile robot to exit from the passage to the panel. In one embodiment, the alignment features may include mounting holes at predetermined locations on the panel for receiving fasteners, thereby allowing one of two possible orientations of the panel to be established during installation. Another prefabricated feature may include fastener holes for receiving fasteners for attaching the panel to a support beam. Furthermore, the panel may include markings indicating the location of through-holes for the application of RFID tags after installation. Furthermore, in one embodiment, additional reference grooves may be cut into the top surface of the panel.

[0047] In block 308, the frame portion of the movable area is attached to the storage structure. In one embodiment, the frame portion may consist of support beams. One end of each support beam may be attached to the corresponding end of the storage structure, more specifically, to a support at the end of the storage structure. The beams may be attached to the storage structure by mounting brackets.

[0048] In block 310, (one or more) panels are oriented according to alignment features. For example, the alignment features may be in the form of mounting holes that allow the panel to be oriented in one of two orientations. Once aligned, the panels can be fixed to the support beams by fasteners. In block 312, a floor of a movable area, composed of panels and supported by a frame portion, is installed. During installation, the panels can be aligned and fixed one by one to form the floor.

[0049] It is assumed that additional features may be applied to the panel after installation. In block 314, reference markers may be applied to the panel after installation. In one embodiment, these reference markers are formed by placing magnets in reference grooves on the upper surface of the panel. At least one reference marker may be applied to the panel after the floor is installed, and at least one reference marker may be configured to facilitate position determination and navigation by a mobile robot moving on the floor.

[0050] In block 316, RFID tags may be applied to the panel after installation. More specifically, at least one RFID tag may be applied to the panel after installation of the floor, and at least one RFID tag may be configured to facilitate position determination and navigation by a mobile robot moving on the floor. These RFID tags may be applied to the bottom surface of the panel. In one embodiment, through holes may be drilled at marked locations on the top surface to facilitate the application of RFID tags. These RFID tags may be applied in addition to or as a substitute for reference markers.

[0051] In block 318, one or more transition plates may be aligned and mounted between the panel and the passageway after installation. In one embodiment, each transition plate may include alignment features such as tabs / extensions with mounting holes aligned with the mounting holes of the panel. These transition plates enable the mobile robot to move from the storage structure to the movement area and vice versa.

[0052] Those skilled in the art will understand that a wide variety of other modifications, changes, and combinations can be made to the above embodiments without departing from the scope of the present invention, and that such modifications, changes, and combinations should be considered to fall within the scope of the concept of the present invention.

Claims

1. An automated storage and retrieval system, wherein the automated storage and retrieval system is A first storage structure comprising a plurality of storage locations configured to store totes for storing goods, wherein the first storage structure comprises a first plurality of paths, each storage location being accessible by the paths, the paths being configured to be traversed by a plurality of mobile robots, and each mobile robot being configured to access a storage location and place or retrieve a tote in the storage location, A mobile area adjacent to the first storage structure and providing a mobile robot with access to enter and exit at least a portion of the path, wherein the mobile area is A frame portion formed by a plurality of beams configured to be connected to the first storage structure, A floor supported by the frame portion, wherein the floor comprises a plurality of panels that collectively define the floor, and at least one panel has one or more guidelines at a predetermined location on the at least one panel for facilitating the movement of the mobile robot thereon, A mobile area equipped with, An automated storage and retrieval system equipped with the following features.

2. The automated storage and retrieval system according to claim 1, wherein the one or more guidelines comprise one or more magnetic guidelines, and the at least one panel further comprises at least one groove configured to receive press-fitting metal material for forming the one or more magnetic guidelines.

3. The automated storage and retrieval system according to claim 2, wherein at least one mobile robot is equipped with a magnetic sensor that detects one or more magnetic guidelines for facilitating the movement of the at least one mobile robot on the at least one panel.

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

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

6. The automated storage and retrieval system according to claim 1, wherein the at least one panel comprises at least one reference marker applied to the upper surface of the at least one panel, and the at least one reference marker is configured to facilitate position determination and navigation by a mobile robot moving on the floor.

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

8. The automated storage and retrieval system according to claim 4, further comprising a transition plate positioned between one of the at least one panels and a corresponding path, wherein the transition plate is configured to be connected to the alignment feature portion of the panel for alignment of the transition plate with the one panel and alignment of the transition plate with the corresponding path.

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

10. The automated storage and retrieval system, A second storage structure comprising a plurality of storage locations configured for storing tote bags for holding goods, wherein the second storage structure comprises a second plurality of paths, and each storage location is accessible by the paths, The automated storage and retrieval system according to claim 9, further comprising a second plurality of mounting brackets, each mounting bracket connecting a second end of each beam to a corresponding end of the second storage structure.

11. A panel for supporting a mobile robot that moves on the panel, wherein the panel is One or more magnetic guidelines are formed at predetermined locations on the upper surface of the panel to facilitate the movement of the mobile robot along the upper surface, At least one groove formed on the upper surface of the panel, wherein the at least one groove is configured to receive a metallic material to form one or more magnetic guidelines, A positioning feature unit configured to align one or more magnetic guidelines with respect to a corresponding path in a predetermined manner, wherein the corresponding path is configured such that a mobile robot enters and exits between the corresponding path and the panel, A panel equipped with this feature.

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

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

14. The aforementioned panel, The panel according to claim 11, further comprising at least one reference marker applied to the upper surface of the panel, the reference marker being configured to facilitate position determination and navigation by a mobile robot.

15. A method for constructing a moving area for an automated storage and retrieval system, wherein the method is A step of connecting the frame portion of the mobile area to the storage structure by connecting a plurality of beams to the storage structure, wherein the storage structure comprises a plurality of storage locations configured to store totes for storing goods, the storage structure comprises a plurality of paths, each storage location is accessible by a path, the paths are configured to be traversed by a plurality of mobile robots, each mobile robot is configured to access a storage location and place or retrieve a tote from the storage location, and the mobile area allows the mobile robots to enter and exit the paths; A step of installing a floor supported by the frame portion, wherein the floor is formed by a plurality of panels that collectively define the floor, and at least one panel has one or more guidelines at a predetermined location on the at least one panel for facilitating the movement of the mobile robot thereon, Methods that include...

16. The method according to claim 15, further comprising the step of receiving the at least one panel, which has at least one groove pre-formed to receive press-fit metal material for forming one or more guidelines, before the installation of the floor.

17. The method according to claim 15, further comprising the step of applying at least one reference marker to the at least one panel after the installation of the floor, wherein the at least one reference marker is configured to facilitate position determination and navigation by a mobile robot moving on the floor.

18. The method according to claim 15, further comprising the step of applying at least one RFID tag to the at least one panel after the installation of the floor, wherein the at least one RFID tag is configured to facilitate position determination and navigation by a mobile robot moving on the floor.

19. The method according to claim 15, further comprising the step of receiving the at least one panel having an alignment feature portion for aligning one or more guidelines with respect to a corresponding path in a predetermined manner, wherein the corresponding path is configured such that a mobile robot enters and exits between the corresponding path and the at least one panel.

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

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