Autonomous guided vehicles

Abstract

To relate generally to storage and take-out systems as a whole, and in particular to the autonomous carriage of a storage and take-out system.SOLUTION: The present invention provides an autonomous carrying robot that carries loaded articles within a storage and take-out system in which the autonomous carrying robot includes a loading bed with at least one reference plane and at least one loaded articles alignment device, and the at least one loaded articles alignment device is configured to place the loaded articles on the loading bed in substantial contact with the at least one reference plane to place the loaded articles in a predetermined position on the loading bed.SELECTED DRAWING: Figure 7A

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application is a non-provisional patent application claiming the benefit of U.S. Patent Application No. 13 / 327,040, filed December 15, 2011, which claims priority to U.S. Provisional Patent Application No. 61 / 423,220, filed December 15, 2010; U.S. Patent Application No. 13 / 326,993, filed December 15, 2011, which claims priority to U.S. Provisional Patent Application No. 61 / 423,388, filed December 15, 2010; and U.S. Patent Application No. 13 / 326,952, filed December 15, 2011, which claims priority to U.S. Provisional Patent Application No. 61 / 423,365, filed December 15, 2010, the disclosures of which are incorporated herein by reference in their entireties.

[0002] [Technical field] The present embodiments relate generally to storage and retrieval systems, and more particularly to autonomous transport of storage and retrieval systems. [Background technology]

[0003] Warehouses that store case units typically include a series of storage racks accessible by transport devices such as forklifts, carts, and elevators, or other lifting and transport devices, that can move in aisles between or along the storage racks. These transport devices may be automatically or manually driven. Items transported to and stored in the storage racks are typically contained in carriers, e.g., storage containers such as trays, totes, or shipping cases, or pallets. Summary of the Invention

[0004] When an automated transport transports cases to and from storage racks, it would be advantageous to be able to position the cases while holding them securely during transport. It would also be advantageous to be able to minimize the number of drive motors for the automated transport and to be able to control the fingers of the transport arm of the automated transport to pick and place case units in storage or conveyor positions. It would also be advantageous to be able to control the fingers of the transport arm of the automated transport with a simple drive system to pick and place case units in storage or conveyor positions. [Brief explanation of the drawings]

[0005] These aspects and other features of the disclosed embodiments are explained in the following description taken in conjunction with the accompanying drawings.

[0006] [Figure 1] 1 is a schematic diagram illustrating an exemplary storage and retrieval system in accordance with an aspect of the disclosed embodiment; [Figure 2] 1 is a schematic plan view of an exemplary storage and retrieval system in accordance with one aspect of the disclosed embodiment; [Figure 3] 1 illustrates a structure of a storage and retrieval system in accordance with an aspect of the disclosed embodiment; [Figure 4A] FIG. 1 illustrates a storage shelf in accordance with an aspect of the disclosed embodiment; [Figure 4B] FIG. 1 illustrates a storage shelf in accordance with an aspect of the disclosed embodiment; [Figure 4C] FIG. 1 illustrates a storage shelf in accordance with an aspect of the disclosed embodiment; [Figure 5] FIG. 1 illustrates an exemplary autonomous guided vehicle in accordance with an aspect of the disclosed embodiment. [Figure 6] FIG. 6 is a schematic diagram illustrating a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 7A] FIG. 6 is a schematic diagram illustrating a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 7B]FIG. 6 is another schematic diagram illustrating a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 7C] FIG. 1 illustrates an exemplary autonomous guided vehicle in accordance with an aspect of the disclosed embodiment. [Figure 8] FIG. 6 is a schematic diagram illustrating a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 9] FIG. 6 is a schematic diagram illustrating a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 10] FIG. 6 illustrates a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 11] FIG. 1 is a flow diagram according to an aspect of the disclosed embodiment. [Figure 12] FIG. 6 is a schematic diagram illustrating a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 13A] FIG. 6 is a schematic diagram illustrating a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 13B] FIG. 6 is a schematic diagram illustrating a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 13C] FIG. 1 is a flow diagram according to an aspect of the disclosed embodiment. [Figure 14] FIG. 6 is a schematic diagram illustrating a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 15A] FIG. 6 is a schematic diagram illustrating a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 15B] FIG. 6 is a schematic diagram illustrating a portion of the example autonomous guided vehicle of FIG. 5 in accordance with an aspect of the disclosed embodiment. [Figure 16] FIG. 6 is a schematic diagram illustrating an interface between a transport arm of the autonomous guided vehicle of FIG. 5 and a shelf of a conveyor in accordance with an aspect of the disclosed embodiment. [Figure 17A] FIG. 1 is a schematic diagram illustrating detection of tilt of an autonomous guided vehicle in accordance with an aspect of the disclosed embodiment. [Figure 17B] FIG. 1 is a schematic diagram illustrating detection of tilt of an autonomous guided vehicle in accordance with an aspect of the disclosed embodiment. [Figure 18] FIG. 1 is a flow diagram according to an aspect of the disclosed embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0007] 1 schematically illustrates an exemplary storage and retrieval system according to an embodiment. Although the disclosed embodiments will be described with reference to the illustrated embodiments, it should be understood that the disclosed embodiments can be embodied in many alternative forms. Furthermore, any suitable size, shape, or type of element or material can be used.

[0008] According to an embodiment, the storage and retrieval system 100 may be substantially similar to those described, for example, in U.S. patent application Ser. No. 12 / 757,381, entitled "STORAGE AND RETRIEVAL SYSTEM," filed April 9, 2010; U.S. Provisional Patent Application Ser. No. 61 / 423,340, entitled "Warehousing Scalable Storage Structure," filed December 15, 2010, attorney docket number 1127P014551-US(-#1) (now U.S. patent application Ser. No. 13 / 326,674, filed December 15, 2011, attorney docket number 1127P014551-US(PAR)), the disclosures of which are incorporated herein by reference in their entireties. The storage and retrieval system 100 may operate, for example, in a retail distribution center or warehouse to fulfill orders received from retail stores for case units (as used herein, case unit refers to items not stored in trays, on totes, or on pallets, e.g., uncontained items, or items stored in trays, totes, or on pallets). Note that a case unit may include a case of items (e.g., a case of soup cans, boxes of cereal, etc.) or individual items adapted to be removed from or placed on a pallet. According to an embodiment, shipping cases or case units (e.g., cartons, barrels, boxes, crates, jugs, totes, pallets, or any other device suitable for holding case units, etc.) may have variable sizes, may be used to hold items in distribution, and may be configured to be palletizable for distribution.For example, it is noted that when a stack or pallet of case units arrives at the storage and retrieval system, the contents of each pallet may be identical (e.g., each pallet holds a predetermined number of identical items - one pallet holds soup and another pallet holds cereal), and when the pallets leave the storage and retrieval system, the pallets may contain any suitable number and combination of different items (e.g., each pallet may hold a different type of item - one pallet holds a combination of soup and cereal). In alternative embodiments, the storage and retrieval systems described herein may be applied to any environment in which case units are stored and retrieved.

[0009] The storage and retrieval system 100 may be configured to be installed in an existing warehouse structure or adapted for a new warehouse structure, for example. In an embodiment, the storage and retrieval system may include infeed and outfeed transfer stations 170, 160, multi-level vertical conveyors 150A, 150B, a storage structure 130, and a plurality of autonomous guided vehicles or robots 110 (referred to herein as "bots"). The storage and retrieval system may also include a robot or bot transfer station (such as that described in U.S. patent application Ser. No. 12 / 757,220, entitled "STORAGE AND Retrieval System," filed April 9, 2010, the disclosures of which are incorporated herein by reference in their entireties), which may provide an indirect interface between the bots 110 and the multi-level vertical conveyors 150A, 150B. The infeed transfer station 170 and the outfeed transfer station 160 may operate in conjunction with their respective multi-level vertical conveyors 150A, 150B to transport case units bidirectionally to and from one or more levels of the storage structure 130. While the multi-level vertical conveyors are described herein as a dedicated inbound or infeed conveyor 150A and a dedicated outbound or outfeed conveyor 150B, it is noted that each of the conveyors 150A, 150B may be used for both inbound and outbound transport of case units / items from the storage and retrieval system. The multi-level vertical conveyors may be any suitable lifting device for transporting case units between levels of the storage and retrieval system. It is noted that while a multi-level vertical conveyor is described herein, in other embodiments the conveyors may be any suitable conveyor or transport / retrieval device having any suitable transport path orientation.Some non-limiting suitable examples of multi-level vertical conveyors are described, for example, in U.S. patent application Ser. No. 12 / 757,354, filed Apr. 9, 2010, entitled "LIFT INTERFACE FOR STORAGE AND RETRIEVAL SYSTEMS," and U.S. Provisional Patent Application Ser. No. 61 / 423,298, filed Dec. 15, 2010, entitled "LIFT INTERFACE FOR STORAGE AND RETRIEVAL SYSTEMS," with attorney docket number 1127P014525-US(-#1) (now U.S. patent application Ser. No. 13 / 327,088, filed Dec. 15, 2011, with attorney docket number 1127P014525-US(PAR)), the disclosures of which are incorporated herein by reference in their entireties. No. 12 / 757,220, entitled "A Multi-Level Vertical Conveyor System," previously incorporated herein by reference. For example, a multi-level vertical conveyor may have any suitable number of support shelves for transporting case units to a predetermined level of the storage and retrieval system. The support shelves may have slatted supports (made of thin, elongated plates) configured to allow fingers of the bot 110 or infeed / outfeed transfer stations 170, 160 to pass between the slats to transport case units to and from the conveyor. It is noted that, in embodiments, the transport of case units between the bot and the multi-level vertical conveyor may be accomplished in any suitable manner.

[0010] As will be appreciated, the storage and retrieval system 100 may include, for example, multiple infeed and outfeed multilevel vertical conveyors 150A, 150B accessible by the bots 110 at each level of the storage and retrieval system 100, thereby enabling one or more case units to be transported from the multilevel vertical conveyors 150A, 150B to each of the storage spaces at each level, and from each of the storage spaces to any one of the multilevel vertical conveyors 150A, 150B at each level. The bots 110 may be configured to transport case units between a storage space and a multilevel vertical conveyor in a one-pick manner (e.g., substantially directly between the storage space and the multilevel vertical conveyor). According to another example, a designated bot 110 may retrieve a case unit from a shelf of a multilevel vertical conveyor, transport the case unit to a predetermined storage area of ​​the storage structure 130, and place the case unit within the predetermined storage area (or vice versa).

[0011] Bot 110 may be configured to position case units, such as the retail items described above, within one or more levels of pick-up stock in storage structure 130 and selectively retrieve ordered items for delivery, for example, to a store or other suitable location. In an embodiment, bot 110 may interface with multi-level vertical conveyors 150A, 150B in any suitable manner, for example, through extension of the bot's transport arm or actuator 1540A (which may have fingers for interfacing with the slatted support shelves of the multi-level vertical conveyor) relative to the bot's frame.Suitable examples of bots are described in U.S. patent application Ser. No. 12 / 757,312, filed April 9, 2010, entitled "AUTONOMOUS TRANSPORTS FOR STORAGE AND Retrieval Systems," U.S. provisional patent application Ser. No. 61 / 423,365, filed December 15, 2010, entitled "AUTOMATED BOT WITH TRANSFER ARM," attorney docket number 1127P014264-US(-#1) (now U.S. patent application Ser. No. 13 / 326,952, filed December 15, 2011, attorney docket number 1127P014264-US(PAR)), entitled "AUTOMATED BOT TRANSFER ARM DRIVE" (now U.S. provisional ...3 / 326,952, filed December 15, 2011, entitled "AUTOMATED BOT TRANSFER ARM DRIVE" (now U.S. provisional patent application Ser. No. 13 / 326,952, filed December 15, 2011, attorney docket number 13 / 326,952, entitled "AUTOMATED B No. 61 / 423,388, filed December 15, 2010, attorney docket number 1127P014265-US(-#1), entitled "BOT HAVING HIGH SPEED SYSTEM" (now U.S. Provisional Patent Application No. 13 / 326,993, filed December 15, 2011, attorney docket number 1127P014265-US(PAR) ... No. 61 / 423,359, filed December 15, 2010, with attorney docket number 1127P014266-US(-#1), entitled "BOT SENSING STABILITY" (now U.S. Provisional Patent Application No. 13 / 326,447, filed December 15, 2011, with attorney docket number 1127P014266-US(PAR)), and No. 61 / 423,206, filed December 15, 2010, entitled "A METHOD AND APPARATUS FOR USE IN A HIGH-FREQUENCY POSITION" and attorney docket number 1127P014267-US(-#1), (now U.S. Patent Application No. 13 / 327,035, filed December 15, 2011, entitled "A METHOD AND APPARATUS FOR USE IN A HIGH-FREQUENCY POSITION" and attorney docket number 1127P014267-US(-#1), the disclosures of which are incorporated herein by reference in their entireties.

[0012] The storage structure 130 may include multiple levels of storage rack modules, each level including an array of storage spaces (arranged in multiple levels and in multiple rows within each level), a pick-up aisle 130A formed between the rows of storage spaces, and a transport deck 130B. Note that each level may also include a bot transport station to provide an indirect interface between the bots and the multi-level vertical conveyor. In an embodiment, the pick-up aisle 130A and the transport deck 130B may be arranged to allow the bots 110 to traverse each level of the storage structure 130 and pick up ordered case units for placement in the pick-up stock. As will be appreciated, the storage and pick-up system may be configured to allow random access to the storage spaces. For example, all storage spaces in the storage structure 130 may be treated substantially equally when determining which storage spaces should be used to pick / place case units from / to the storage structure 130, so that any storage space of sufficient size can be used to store items. Additionally, the storage structure 130 of the embodiment may be arranged so that there is no vertical or horizontal division of the storage structure. For example, each multilevel vertical conveyor 150A, 150B may be common to all storage spaces (e.g., an array of storage spaces) within the storage structure 130, allowing any bot 110 to access each storage space, and any multilevel vertical conveyor 150A, 150B may receive case units from any storage space on any level, so that multiple levels within the array of storage spaces essentially function as a single level (e.g., no vertical division). Multilevel vertical conveyors 150A, 150B may also receive case units from any storage space on any level of the storage structure 130 (e.g., no horizontal division). It should be noted that the storage and retrieval system may also be configured so that each multilevel vertical conveyor serves a predetermined area of ​​the array of storage spaces.

[0013] The storage structure 130 may also include a charging station 130C, for example, to charge the battery pack of the bot 110. In an embodiment, the charging station 130C may be located, for example, in the transport area 295 ( FIG. 2 ) of the transport deck 130B, thereby allowing the bot 110 to substantially simultaneously transport items to and from the multi-level vertical conveyors 150A, 150B, for example, while being charged. The bots 110 and other suitable features of the storage and retrieval system 100 may be controlled, for example, by one or more central system control computers (e.g., control servers) 120 via any suitable network 180. The network 180 may be a wired network, a wireless network, or a combination of wireless and wired networks using any suitable type and / or number of communication protocols. It is noted that in an embodiment, system control server 120 may be configured to manage and coordinate all operations of storage and retrieval system 100, such as in conjunction with warehouse management system 125 to manage the warehouse facility as a whole. Control server 120 may be substantially similar to that described in U.S. patent application Ser. No. 12 / 757,337, entitled "CONTROL SYSTEM FOR STORAGE AND RETRIEVAL SYSTEMS," filed April 9, 2010, the disclosure of which is incorporated herein by reference in its entirety.

[0014] 2, an exemplary configuration of storage and retrieval system 100 is shown. Other suitable exemplary configurations of storage and retrieval systems can be found, for example, in U.S. Provisional Patent Application No. 61 / 423,340, entitled "Warehousing Scalable Storage Structure," filed December 15, 2010, and attorney docket number 1127P014551-US(-#1) (now U.S. Patent Application No. 13 / 326,674, entitled "Warehousing Scalable Storage Structure," filed December 15, 2011, and attorney docket number 1127P014551-US(PAR)), and U.S. Patent Application No. 12 / 757,381, entitled "STORAGE AND Retrieval System," filed April 9, 2010 (the disclosures of which applications are incorporated herein by reference in their entireties). It should be understood that the storage and retrieval system may have any suitable configuration. As can be seen in FIG. 2 , the storage and retrieval system 200 is configured as a single-ended retrieval structure, with only one side of the system 200 having a transport section or deck 130B, for illustrative purposes only. A single-ended retrieval structure may be used, for example, in a building or other structure having a loading dock located on only one side of the building. In an embodiment, the storage and retrieval system 200 includes a transport deck 130B and a retrieval aisle 130A that enable the bot 110 to traverse an entire level of the storage structure 130 in which the bot 110 is located to transport items between any suitable storage location / retrieval aisle 130A and any suitable multi-level vertical conveyors 150A, 150B. The multi-level vertical conveyors 150A, 150B provide for the transport of case units into the storage and retrieval system 200 through an input workstation 210 and for the transport of case units out of the storage and retrieval system 200 through an output workstation 220.In an embodiment, the storage and retrieval system 200 includes first and second storage sections 230A, 230B arranged side by side, with the retrieval paths of each section being substantially parallel to one another and facing the same direction (e.g., toward the transport deck 130B). It is noted that the storage and retrieval system may have any suitable number of storage sections arranged relative to one another in any suitable configuration.

[0015] 1, 3, 4A, 4B, and 4C, each of the storage bays 510, 511 of the storage structure 130 may hold retrieval inventory on a storage shelf 600 separated by an aisle space 130A. In embodiments, the storage bays 510, 511 and the storage shelf 600 may be substantially similar to those described, for example, in U.S. patent application Ser. No. 12 / 757,220 entitled "STORAGE AND RETRIEVAL SYSTEM" and U.S. patent application Ser. No. 12 / 757,381 entitled "STORAGE AND RETRIEVAL SYSTEM" (both previously incorporated by reference). The storage shelf 600 may include, for example, one or more support legs 620L1, 620L2 extending from horizontal supports 610, 611, 613 (which are in turn supported by a vertical support 612). The support legs 620L1, 620L2 may have any suitable configuration, for example, they may be part of a generally U-shaped channel 620 such that the legs are connected to each other via channel portion 620B. Channel portion 620B may provide an attachment point between the channel 620 and one or more horizontal supports 610, 611, 613. Note that each of the support legs 620L1, 620L2 may be configured to be individually attached to the horizontal supports 610, 611, 613. In an embodiment, each of the support legs 620L1, 620L2 includes a bent portion 620H1, 620H2 having an appropriate surface area configured to support a case unit stored on the shelf 600. The bent portions 620H1, 620H2 may be configured to substantially prevent deformation of the case unit stored on the shelf. It is noted that the folded portions 620H1, 620H2 may have a suitable thickness or any other suitable shape and / or configuration to support the case units stored on the shelf. As shown in Figures 4A, 4B, and 4C, the support legs 620L1, 620L2 or channel 620 may form a slatted or corrugated shelving structure.For example, the space 620S between the support legs 620L1, 620L2 allows the arms or fingers of the bot 110 to reach into the shelf to transport case units to and from the shelf. Also, note that the transport of items to and from the multi-level vertical conveyors 150A, 150B (whether the transport is directly or indirectly accomplished by the bot 110) may occur in a manner substantially similar to that described above with respect to the storage shelf 600. Note that the spacing between case units on the shelf may be any suitable spacing. Note that the transport of case units to and from the multi-level vertical conveyors 150A, 150B (whether the transport is directly or indirectly accomplished by the bot 110) may occur in a manner substantially similar to that described above with respect to the storage shelf 600.

[0016] Referring to FIG. 5, an exemplary bot 110 is shown. In an embodiment, the bot 110 includes a longitudinally extending frame 110F having a first end 1500 and a second end 1501, with a longitudinal axis 6000 extending from the first end 1500 to the second end 1501. At least one drive section 110D may be coupled to either the first end 1500 and / or the second end 1501 in any suitable manner to drive the bot 110 along the transport deck 130B and the retrieval aisle 130A (FIG. 1). The drive section 110D may include drive wheels, tracks, or any other suitable drive mechanism to move the bot along the transport deck 130B and the retrieval aisle 130A. The other end of the bot 110 may have any suitable support, such as caster wheels, fixed wheels, movable wheels, and similar mechanisms for movably supporting the bot 110 as it moves along the transport deck 130B and the retrieval aisle 130A. The bot 110 may have any suitable controller 1220 (FIG. 1) to enable operation of the bot 110 (described herein) and / or to enable communication between the bot 110 and the control server 120 (FIG. 1). It should be understood that the bot configurations shown in the figures are merely exemplary, and that the bot may have any suitable configuration for detecting and locating case units relative to the bot 110 as described herein.

[0017] 5, 6, 7A, and 7B, the frame 110F of the bot 110 forms a load bed 1510 configured to hold a case unit (or pick face, which is one or more cases to be picked up and carried by the bot 110) or any other suitable load. The load bed 1510 may be appropriately sized to receive (e.g., hold) any case unit 1700 (or pick face 1700P, which is one or more cases to be picked up and carried by the bot 110) to be transported to or retrieved from the storage and retrieval system 100. For example, in an embodiment, the load bed 1510 may be larger than the expected pick size (i.e., larger than the pick face 1700P that the bot is expected to pick up, for example, from a storage shelf 600 or from any other suitable component of the storage and retrieval system, such as a multi-level vertical conveyor). In this example, the pick face 1700P is shown to include two case units 1700 arranged horizontally relative to the longitudinal axis 6000 of the bot 110. However, the pick face may include any suitable number of case units arranged horizontally, vertically, or in a horizontal and vertical grid.

[0018] The load bed 1510 may include any suitable guide surfaces for unobstructed transport of case units onto the load bed 1510. For example, in an embodiment, the frame 110F forming the load bed 1510 may include one or more flanges 1510C1, 1510C2 on the sides 1510S1, 1510S2 of the load bed 1510. In this example, the flanges 1510C1, 1510C2 may be chamfered or angled at the top opening 1510TP of the load bed 1510. The angled surfaces form a generally wedge shape such that, during transport of the pick face into the loading area (e.g., lowering the case unit into the loading area in the direction of arrow 1673), the angled surfaces guide the case unit 1700 of the pick face 1700P unobstructed into the loading area (e.g., the case unit is hooked onto or received by a portion of the bot 110). The unobstructed transport of the case unit into the bot loading area facilitates loading of the case unit in one pick (e.g., without substantially repositioning the pick face or reloading the pick face into the bot 110). In this example, flanges 1510C1, 1510C2 are shown with generally straight surfaces, but it should be understood that the flanges may be of any suitable shape and / or configuration, such as arcuate, for illustrative purposes only. Also, in this example, flanges 1510C1, 1510C2 are shown as terminating substantially at edge 1510E of the loading area, but it should be understood that they may extend beyond edge 1510E. Furthermore, the flanges may be movable or retractable so that when case units are loaded onto the loading bed 1510, the flanges move and extend beyond edge 1510E to guide the case units into the loading area, and once the case units are loaded, the flanges retract so that they do not protrude beyond edge 1510E. The flanges may also be pivotable between a vertical upright position and an inclined position, for example, as shown in FIG. 7B.

[0019] The fence 1510F may be installed in the side opening 1510P of the load bed 1510. In embodiments, the fence 1510F may be attached to the frame 110F in any suitable manner, such as with fasteners or by welding. Note that the fence 1510F may form part of the frame 110F or may be integral with the frame 110F. In embodiments, the fence may include slots 1510FS disposed between the stop members 1510FM. The slots 1510FS may be configured to extend through the fence 1510F between the stop members 1510FM at a substantially lower position so that the fingers 1540 can extend, for example, below the case units into the storage shelf 600. The stop members 1510FM may be configured to extend above the load bed 1510, thereby providing an obstacle that substantially prevents the case units from exiting the load bed 1510 when placed on the load bed 1510. In this example, the number of slots 1510FS is the same as the number of fingers 1540, however, in alternative embodiments, the fence 1510F may be configured so that multiple fingers 1540 pass through a single slot (e.g., the number of slots is less than the number of fingers). It should also be noted that the fence may have any suitable configuration for preventing the case units from leaving the loading area when they are carried by the bot 110. For example, the fence may be movable such that a stop member is retractable to prevent the case units from leaving the loading area when the fence is extended.

[0020] The bot 110 may include a transport arm or end effector 1540A. Referring to FIGS. 5 and 6, the transport arm 1540A may include a finger 1540 and a movable member 1535. The finger 1540 may extend generally transverse to the bot's longitudinal axis 6000 and may be configured to align with the slatted shelving structure of the storage shelf 600 (FIGS. 4A, 4B, and 4C). The finger 1540 may be movable in the direction of arrow 1673 (e.g., generally perpendicular to the direction of finger extension and retraction 1550) along a lift axis between a lowered position and a raised position. Note that when in the lowered position, the finger 1540 is disposed below the surface of, or at least forms a portion of, the load bed 1510. The fingers may be driven individually or in unison by any suitable drive, as described below, to lift a pick face placed on the finger over the fence 1510F and into or out of the load bed 1510 of the bot 110.

[0021] The load bed 1510 may include any suitable load support for supporting the case units as they are carried by the bot 110. For illustrative purposes only, in an embodiment, the load support may include a "floating" (or movable) bed. An example of a load support surface is a roller bed, as described in U.S. Provisional Patent Application No. 61 / 423,220, entitled "BOT PAYLOAD ALIGNMENT AND SENSING," filed December 15, 2010, attorney docket number 1127P014263-US(-#1) (now U.S. Patent Application No. 13 / 327,040, filed December 15, 2011, attorney docket number 1127P014263-US(PAR)), previously incorporated herein by reference. For example, the bed may include rollers 1510R, each with its axis of rotation generally transverse to the longitudinal axis 6000 of the bot 110. The load supports may be belts, ball bearings, or any suitable "floating" support that move the case units on the load bed to at least partially align the case units with the load bed / bot, as described in more detail below. Each roller may be supported within the frame 110F in any suitable manner. In this example, the roller may be rotatably supported at least in part at one end by a fence 1510F adjacent a side opening 1510P in the load bed 1510, and at the other opposite end by any suitable frame member, such as frame member 110M (FIG. 9). In an embodiment, the rollers 1510R (or other suitable load supports) may be interleaved with the fingers 1540 of the bot 110. It is noted that the roller 1510R and the finger 1540 may be positioned relative to one another in any suitable manner. As will be described in more detail below, the roller may be connected to any suitable drive 1532 (FIG. 8) for rotating the roller 1510R about its axis to move the case unit on the load bed 1510.For purposes of example only, as shown in FIG. 8, the drive 1532 may be a belt and pulley drive 1533, although it should be understood that the drive 1532 may be any drive capable of rotating the roller 1510R.

[0022] The fingers 1540 of the bot 110 extend transversely to the bot's longitudinal axis 6000 and can move in the direction of arrow 1673 (e.g., generally perpendicular to the finger extension and retraction direction 1550). The fingers may be driven by any suitable drive to lift the pick face 1700P over the fence 1510F and into or out of the load bed 1510 of the bot 110. An example of a drive device for driving the finger 1540 can be found in U.S. Provisional Patent Application No. 61 / 423,388, entitled "AUTOMATED BOT TRANSFER ARM DRIVE SYSTEM," filed December 15, 2010, attorney docket number 112P014265-US(-#1) (now U.S. Patent Application No. 13 / 326,993, filed December 15, 2011, attorney docket number 112P014265-US(PAR)), which is incorporated by reference herein.

[0023] Each finger 1540 may include an attachment member 1671 and an arm 1541 having a first end 598 and a second end 599. The attachment member 1671 may be coupled to the first end 598 of the arm 1541, while the second end 599 may be distally disposed from the attachment member 1671. Each finger 1540 may be cantilevered and movably coupled to the movable member 1535, thereby allowing the finger to extend and retract relative to the load bed 1510 (e.g., by lateral movement of the movable member 1535) in the direction of arrow 1550 to interact with, for example, the slats of the storage shelf 600 and the slatted shelves 720 of the multi-level vertical conveyors 150A, 150B ( FIG. 7 ). For example, the attachment member 1671 of each finger 1540 extends from the first end 598 of the finger 1540. It is noted that while fingers 1540 are shown as being composed of different parts 1541, 1671, fingers 1540 may be a single, unitary structure. Movable member 1535 may include guides 1670, with each mounting member 1671 and each guide 1670 configured such that mounting member 1671 is slidable along guide 1670 in the direction of arrow 1673 (e.g., along a lift axis that is generally perpendicular to direction 1550 of lateral movement of transport arm 1540A). In an embodiment, guide 1670 is shown as a rail, but it is noted that guide 1670 may be any suitable member for controllably moving each finger 1540, for example, in the direction of arrow 1673 relative to movable member 1535. In this example, all of the fingers 1540 (regardless of whether the fingers are in a raised or lowered position) move as a unit with the movable member 1535 by the single axis drive 1531 as the fingers extend or retract laterally in the direction of arrow 1550. However, the movable member 1535 and / or fingers 1540 may be configured to move each finger 1540 laterally in the direction of arrow 1550 independently of the other fingers 1540.It is also noted that movable member 1535 and / or fingers 1540 may be configured such that groups of fingers move laterally in the direction of arrow 1550 independently of other groups of fingers.

[0024] At least one driver 1672 may be attached to the movable member 1535 and may be coupled to a first end of one or more fingers 1540 in any suitable manner for driving the one or more fingers along the guide 1670 in the direction of arrow 1673 along the lift axis. Note that the at least one driver 1672 may be coupled to any portion of the one or more fingers 1540 for driving the fingers along the guide 1670. In embodiments, each finger 1540 may have a respective driver 1672, such that each finger 1540 can be raised or lowered independently, or a single driver may drive multiple fingers along their respective guides (or, for example, some fingers can move individually and other fingers can move in groups). The driver 1672 may be any suitable driver capable of driving the fingers along the lift axis in the direction of arrow 1673. An example of a suitable drive unit is described, for example, in U.S. Provisional Patent Application No. 61 / 423,388, entitled "AUTOMATED BOT TRANSFER ARM DRIVE SYSTEM," filed December 15, 2010, with attorney docket number 1127P014265-US(-#1) (now U.S. Patent Application No. 13 / 326,993, filed December 15, 2011, with attorney docket number 1127P014265-US(PAR)), the entire disclosure of which is incorporated herein by reference. For example, the drive unit may include a stepper motor 1672D (FIG. 12) configured to drive any suitable linear actuator, such as a ball screw 1672S (FIG. 12). The drive unit may also include any suitable motor capable of tracking the number of revolutions or a portion of the revolutions of the motor. It is noted that, for purposes of example only, the drive and guide may be integrated together, such as a chain / belt and sprocket / pulley arranged to carry the fingers in the direction of arrow 1673.In embodiments, each driver 1672 may be selectable, for example, by the bot controller 1220 (or any other suitable controller, such as, for example, the control server 120), and may be independently operable to lift each finger 1540. The driver 1672 may be coupled to the first end 598 (FIG. 7A) of the finger 1540, for example, by any suitable linkage 1672C. In embodiments, each driver 1672 may be selectably coupled to each finger 1540 by a removable (e.g., mechanical, magnetic, etc.) linkage 1672C, or the driver 1672 may be substantially permanently coupled to each finger, for example, by a pivotable, rotatable, or other movable joint or coupling. Note that, for purposes of example only, the driver and guide may be integrated with each other, such as in the case of a chain / belt and sprockets / pulleys arranged to carry the fingers in the direction of arrow 1673. In an embodiment, each drive device 1672 may be selectable, for example, by the bot controller 1220, or may be independently operable to lift each finger 1540. However, it should be noted that any suitable controller, such as, for example, the control server 120, may select which drive device to activate. In one aspect, the storage and retrieval system may include case unit and / or pick face sensors to measure one or more dimensions of one or more case units and pick faces formed by the case units. For example, the in-feed transfer station 170 may include any suitable sensor CS (FIG. 1) to measure one or more dimensions of the case units and / or pick faces (FIG. 13C, block 9000). The bot 110 may also include any suitable sensor PS (FIG. 5) installed on the load bed, for example, to measure one or more dimensions of the case units and / or pick faces carried by the bot 110.In other embodiments, any suitable sensors may be positioned in any suitable location in the storage and retrieval system to measure one or more dimensions of the case unit and / or pick face. The sensors CS, PS may communicate with one or more bot controllers and control server 120, and the one or more dimensions of the case unit and / or pick face may be stored in any suitable memory of the bot controller and / or control server 120. As described above, when the drive unit 1672 for lifting the finger 1540 is activated, the bot controller and / or control server 120 may use the case / pick face data obtained from one or more sensors CS, PS to determine which drive unit 1672 to drive (e.g., which finger to lift) ( FIG. 13C , block 9010) depending on the case dimensions identified by the case / pick face data. As will be appreciated, data from the position of the case unit / pick face in the load bed, e.g., data determined by the bot's sensor PS, may also be used to determine which drive 1672 / fingers 1540 to activate / lift. In embodiments, each drive 1672 may be selectably coupled to each finger 1540 by a removable (e.g., mechanical, magnetic, etc.) linkage 1672C, or the drive 1672 may be substantially permanently coupled to each finger by, e.g., a pivotable or other movable joint or coupling.

[0025] As described herein, to lift the fingers 1540, each driver 1672 may be suitably connected to, for example, the bot controller 1220 or any other suitable controller (such as, by way of example only, the control server 120). The bot controller 1220 may be configured to selectively activate each driver 1672 to simultaneously lift and lower any desired number of fingers 1540. The size of the pick face to be picked by the bot 110 may be measured in any suitable manner, such as by a sensor installed on the bot, or by any suitable table or other information stored in the memory of the bot controller 1220, the control server 120, the warehouse management system 2500, or any other suitable memory. Depending on the size of the pick face, an appropriate number of fingers 1540 may be selected for activation, such that the pick face is substantially uniformly supported by the fingers 1540 of the transport arm 1540A. To drive the motors 1672D through the same rotational angle to raise (or lower) the selected fingers 1540 in unison, the controller 1220 may be configured to send start and stop commands to the motors 1672D ( FIG. 12 ) for the selected fingers 1540, thereby causing the selected fingers 1540 to start / stop at approximately the same height and at approximately the same time. Note that the motors 1672D may be coupled to the controller 1220, allowing the controller 1220 to select which motors 1672D to send commands to, e.g., which motors 1672D to operate or idle ( FIG. 9 , block 18000). As will be appreciated, the coupled relationship between the motors 1672D and the controller 1220 allows the selected motors to be operated with only one command signal to start and stop the selected motors ( FIG. 9 , block 18010). By operating the motors 1672D with only one start / stop command signal, the selected motors can be started and stopped at approximately the same time, thereby causing approximately the same rotation.Note that while any suitable sensors on the fingers (as described below) may provide position data, this position data may not be necessary for a closed-loop position feedback system (e.g., stepper motor feedback) such as that formed by the geared motor 1672D and controller. In one embodiment, the sensors on the fingers (described below) may be used to verify the position of the fingers as determined by the closed-loop feedback system. In other embodiments, the sensors on the fingers may be an open-loop system or may be used instead of or in addition to a closed-loop feedback system.

[0026] The case unit contact member 1530 may be movably mounted at least partially within the loading area and removably coupled to a movable member 1535 for extending and retracting the transfer arm 1540A in the direction of arrow 1550, for example, in the manner described in U.S. Provisional Patent Application No. 61 / 423,365, entitled "AUTOMATED BOT WITH TRANSFER ARM," attorney docket number 1127P014264-US(-#1), previously incorporated by reference herein (now U.S. Patent Application No. 13 / 326,952, attorney docket number 1127P014264-US(PAR), filed December 15, 2011). It is noted that the case unit contact member 1530 may include any suitable slot 1680 that allows each finger to be lifted in the direction of arrow 1673 without substantially contacting the case unit contact member 1530. In this example, the case unit contact member has a slot 1680 for each finger 1540, although it should be understood that the slots 1680 may have any suitable configuration, such as, for example, a configuration that allocates one slot for multiple fingers 1540. The case unit contact member 1530 may be driven laterally in the direction of arrow 1550 by any suitable drive 1531. For purposes of example only, the drive 1531 may be a belt and pulley drive 1534 ( FIG. 9 ), although it should be understood that the drive may be any suitable drive for moving the case unit contact member in the direction of arrow 1550. In an embodiment, both the case unit contact member 1530 and the movable member 1535 (together with the fingers 1540) are configured to move laterally in the direction of arrow 1550. The case unit contact member 1530 may be configured to move along rails 1530R1, 1530R2. The rails 1530R1, 1530R2 may be attached to the frame 110F in any suitable manner to guide the movement of the case unit contact member 1530 and the movable member 1535.It should be understood that in embodiments, movement of the case unit contact member 1530 and the movable member 1535 in the direction of arrow 1550 may be guided in any suitable manner, such as by separate rail systems (e.g., each of the case unit contact member 1530 and the movable member 1535 has a separate rail). For illustrative purposes only, and with reference to FIGS. 5 and 7 , each of the case unit contact member 1530 and the movable member 1535 may have a slide member 1530D1, 1530D2, 1535D1, 1535D2, respectively, for movably coupling the case unit contact member 1530 and the movable member 1535 to the rails 1530R1, 1530R2. One or more slide members 1530D1, 1530D2, 1535D1, 1535D2 may be positioned or suitably sized to extend along the rails to support a pick face supported on the cantilevered fingers 1540 of the transport arm 1540A. For example, as described in U.S. Provisional Patent Application No. 61 / 423,220, entitled "BOT PAYLOAD ALIGNMENT AND SENSING" and attorney docket number 1127P014263-US(-#1), which has already been incorporated by reference herein (now U.S. Patent Application No. 13 / 327,040, filed December 15, 2011, and attorney docket number 1127P014263-US(PAR)), the case unit contact members 1530 may be independently movable in the direction of arrow 1550 to engage or position a case unit placed on the load bed 1510.

[0027] As will be described in more detail below, with reference to FIGS. 6 and 10 , the case unit contact members 1530 may be configured to allow movement of the fingers in the direction of arrow 1673 (e.g., perpendicular to the plane of extension and retraction of the case contact members 1530 and fingers 1540 in the direction of arrow 1550). For example, the case unit contact members 1530 may include any suitable slots 1680 that allow each finger to be lifted in the direction of arrow 1673 without substantially contacting the case unit contact members 1530. In this example, the case unit contact members have a slot 1680 for each finger 1540, but it should be understood that the slots 1680 may have any suitable configuration, such as, for example, a configuration in which one slot is allocated for multiple fingers 1540. As described above, the fence 1510F includes slots 1510FS that allow the fingers 1540 to pass through the fence 1510 in substantially lowered and raised positions when transporting case units to and from the load bed 1510.

[0028] 7C , the bot 110 may include one or more side blades 1535G attached to the bot arm 110A. To align a pick face (e.g., one or more case units 1700A) on the bot arm 110A, the one or more blades 1535G may be moved along the longitudinal axis 6000 of the bot 110 in the direction of arrow 1550X. Translational movement of the one or more side blades 1535G may enable positioning of the bot load at any location along the bot's longitudinal axis within the bot loading area and may provide fine adjustment for positioning the case on the storage shelf 600. Note that in this embodiment, the side blades 1535G do not carry, transport, or lift the case unit 1700A, but may assist in controlling the case unit 1700A while it is being retrieved and placed. Note that one side blade 1535G may be fixed and serve as a reference point for aligning the case unit 1700A.

[0029] 1, 6, 7A, and 7B, the bot 110 may also include any suitable sensor 1703 for detecting the pick face 1700P (and the case units 1700 that make up the pick face) as the pick face 1700P is transported to and from the load bed 1510. In an embodiment, the sensor 1703 may be a through-beam sensor. The sensor 1703 may include, for example, a transmitter 1701 and a receiver 1702 mounted (in any suitable manner) to a frame adjacent the side opening 1510P of the load bed 1510. The sensor 1703 may be configured and installed on the bot 110 to detect the edge of the pick face 1700P as the pick face 1700P is transported, for example, between the storage shelf 600 or the multi-level vertical conveyors 150A, 150B and the load bed 1510. In an embodiment, sensor 1703 may be configured to detect leading edge 1700A and trailing edge 1700B of pick face 1700P as pick face 1700P passes by sensor 1703, for example, to measure depth D of pick face 1700P. It should be understood that the sensor may be configured to detect any suitable feature of pick face 1700P (e.g., pick face as a single entity and / or each case unit of the pick face) to measure any suitable dimension of pick face 1700P, for example. In an embodiment, bot controller 1220 (or any other suitable controller, such as, for example, control server 120) may be configured to record detection signals from sensor 1703 while case units are transported to and / or from bot 110. The bot controller 1220 may be configured to respond to detection of the leading edge 1700A and trailing edge 1700B of the pick face 1700P to measure the depth D of the pick face 1700P. As will be appreciated, which edge of the pick face is the leading edge depends on the direction in which the pick face 1700P is conveyed.For example, when the pick face 1700P enters the load area, the edge closest to the case unit contact member 1530 is the leading edge, and when the pick face 1700P exits the load area, the edge closest to the case unit contact member 1530 is the trailing edge of the pick face 1700P. By way of example only, the controller 1220 may be configured to use the leading edge and trailing edge sensor signals along with any other suitable information / data (e.g., indexing of the drives that drive the movement of the fingers 1540 as they are extended or retracted from / into the load bed area) to measure the depth D of the pick face.

[0030] The sensor 1703 may also be configured to detect whether the pick face 1700P extends beyond the opening 1510P of the load bed 1510. If the pick face extends beyond the opening of the load bed 1510, the controller 1220 may be configured to time out the bot 110 (e.g., a stop operation) so that corrective action can be taken if such a "protrusion" of the load is detected. Such corrective action may include, but is not limited to, returning the load to the storage shelf 600 from which the case was removed, or, if the case was removed from the multi-level vertical conveyor, returning the load to a storage shelf where the case unit / pick face can be inspected and redirected to an appropriate location within the storage and retrieval system. Such corrective action may also include the bot stopping the multi-level vertical conveyor via communication between the bot and the multi-level vertical conveyor or, for example, via communication with the control server 120 (or any other suitable controller in communication with both the bot and the multi-level vertical conveyor). As will be appreciated, the bot may include other suitable sensors to measure how far the pick face 1700P extends beyond the opening 1510P in the load bed 1510, in which case the controller 1220 simply redirects the bot 110, for example, to an inspection area, if the pick face protrudes less than a predetermined amount. The predetermined amount of protrusion may be any suitable protrusion distance such that the protruding pick face does not contact the storage and retrieval system, other bots, or other pick face structures, for example, while moving to the inspection area. As will also be appreciated, the sensor 1703 may be used to detect and measure any gaps between the casings of the pick faces.

[0031] In an embodiment, the bot 110 may have any suitable sensor for detecting the length L (FIG. 7) of the pick face 1700P. For example, the bot 110 may have sensors 1713A, 1713B disposed at opposite longitudinal ends of the load bed 1510. By way of example only, the sensors 1713 may be, for example, a contact plate, a through-beam sensor, a load cell, or any other suitable sensor that detects substantial contact between the case unit and the side of the load bed 1510. The bot controller 1220 may also be configured to monitor the load on the drive unit 1532 (e.g., a rise in current, etc.) to detect substantial contact between the case unit 1700 and the sides 1510S1, 1510S2. Although the sensor 1713 is shown in the figure as being positioned adjacent to sides 1510S1 and 1510S2, it should be understood that the sensor 1713 may be positioned in any suitable location on the bot 110 to detect substantial contact between the case unit and sides 1510S1 and 1510S2.

[0032] In an embodiment, when the pick face 1700P is placed, for example, on the rollers 1510R of the load bed 1510, the rollers may be driven in the first direction 1551 until the pick face 1700P is detected by a first one of the sensors 1713A, 1713B (e.g., the pick face substantially contacts the sides 1510S1, 1510S2 of the load bed 1510). A first detection signal indicating that the pick face has been placed on the first side of the load bed 1510 may be sent, for example, to the bot controller 1220. If the pick face includes multiple case units, the rollers may continue to be driven for a predetermined time after the first case unit of the pick face 1700P is detected by the sensors 1713A, 1713B, so that the remaining case units 1700 of the pick face 1700P also substantially contact the sides 1510S1, 1510S2 of the load bed 1510. The rollers may then be driven in the opposite direction 1551, causing the pick face to move toward and be detected by another sensor 1713A, 1713B located on the opposite side of the load bed 1510 (e.g., substantially contacting the other side 1510S1, 1510S2). A second detection signal indicating that the pick face is located on the second side of the load bed 1510 may be sent, for example, to the bot controller 1220. Again, if the pick face 1700P includes multiple case units, the rollers may continue to be driven for a predetermined time after the first one of the case units is detected by the sensors 1713A, 1713B to allow the other case units of the pick face to substantially contact the sides 1510S1, 1510S2. The bot controller 1220 may be configured to measure the length L of the pick face using the first and second detection signals from the sensors 1713A, 1713B, for example, in combination with data regarding the operation of the bed drive or motor 1532. It should be understood that the length L of the pick face 1700P may be measured in any suitable manner, using any suitable sensor, by any suitable processor or controller.In one example, the bot 110 may be configured to send pick face measurement data, for example to the control server 120, to determine the pick face measurement.

[0033] 1, 5, 6, 7A, 7B, 8, 10, and 11, an exemplary operation of the bot 110 will be described. The bot 110 may be instructed, for example, by the control server 120, to retrieve a pick face 1700P from the multi-level vertical conveyor 150A or the storage shelf 600. The bot 110 extends the fingers 1540 through the slots 1510FS of the fence 1510F and beneath the case unit to be retrieved. The pick face is lifted by the fingers 1540 and carried to the load bed area. As can be appreciated, the fingers 1540 may be raised so that, as the case unit is transported to and from the loading area of ​​the frame 110F, the case unit is carried above the stop members 1510FM of the fence without substantially contacting the stop members 1510FM. As the fingers are retracted into the load bed area, the controller 1220 measures the depth D of the pick face 1700P, as described above (FIG. 11, block 1102). For example, as the pick face 1700P is conveyed to the loading area of ​​the robot 110, the sensor 1703 detects the gaps between the cases forming the pick face, for example, if the pick face includes multiple cases, as well as the first or leading edge 1700A and the second or trailing edge 1700B of the pick face 1700P. As described above, the controller 1220 detects signals from the sensor 1703 corresponding to the detection of the first and second edges 1700A, 1700B, and measures the depth D of the pick face 1700P conveyed to the loading area, along with other appropriate information (e.g., data related to the operation of the drive motors for extending / retracting the fingers).

[0034] The bot controller 1220 and / or control server 120 may be programmed with the expected depth of the pick face 1700P to be picked by the bot. In an embodiment, the bot controller 1220 may communicate with the control server 120 and inform the control server of the pick face depth D. If the measured pick face depth D matches the expected pick face depth, confirmation that the correct pick face 1700P has been picked may be sent by the control server 120 to the bot controller 1220, which instructs the bot 110 to proceed with the delivery of the pick face 1700P. In an embodiment, if the measured pick face depth D does not match the expected pick face depth, the control server 120 instructs the bot 110 to return the pick face 1700P to the storage shelf 600 from which the pick face 1700P was retrieved, or instructs the bot 110 to redirect the pick face 1700P, for example, to an area of ​​the storage and retrieval system where the pick face can be inspected. In an embodiment, if the measured pick face depth D does not match the expected pick face depth, the bot 110 verifies its position within the storage and retrieval system 100 and / or re-measures the depth D of the case unit. If, after the bot's position verification and / or re-measurement of the pick face depth, it is determined that the pick face depth D is incorrect, a fault signal may be sent, for example, to the control server 120, and the bot may return the pick face 1700P to the storage shelf 600 from which it was retrieved, or may redirect the pick face 1700P to any other suitable location within the storage and retrieval system. The bot 110 may then proceed to, for example, another storage location, a multi-level vertical conveyor, etc., to retrieve another case unit.

[0035] If the pick face 1700P is confirmed to be the correct case unit, the pick face 1700P may be configured to be aligned with a predetermined position on the load bed 1510 when the case unit is transported to the loading area of ​​the frame 110F (FIG. 11, block 1103). For example, after the fingers are retracted and the case unit is set above the load bed 1510, the fingers 1540 may be lowered so that the pick face 1700P is supported, for example, by the rollers 1510R (or any other suitable support) of the load bed 1510. To measure the length of the pick face, the robot 110 may drive the rollers 1510R so that the pick face 1700P is positioned substantially in contact with the sides 1510S1, 1510S2 of the load bed 1510, as described above. When the pick face 1700P substantially contacts the sides 1510S1, 1510S2, the bot controller 1220 may detect a signal from one of the sensors 1713A, 1713B, as described above, and after a predetermined time, instruct the drive unit 1532 to stop driving the roller 1510R, so that all case units 1700 of the pick face substantially contact the sides 1510S1, 1510S2. As will be understood, movement of the pick face in the direction of the arrow 1551 (e.g., in the direction of the longitudinal axis 6000 of the bot 110) records or determines the position of the pick face 1700P relative to the bot 110 along one axis (e.g., the longitudinal axis of the bot).

[0036] The bot 110 may also be configured to record the position of the pick face 1700P along a second axis (e.g., the bot's horizontal axis), thereby determining the lateral and vertical positions of the pick face 1700P relative to the bot 110. For example, the second reference plane may be formed by, for example, the fence 1510F. Note that the first and second reference planes may be formed by any suitable feature of the load bed 1510. In an embodiment, the case unit contact member 1530 may be operated by any suitable driver, such as driver 1531, to move the case unit contact member 1530 toward the side opening 1510P of the load bed 1510 to substantially contact and press the pick face 1700P against the fence 1510F to position the pick face 1700P laterally relative to the bot 110. To detect substantial contact between the pick face and the fence 1510F, the bot may have any suitable sensor 1714, which may be substantially similar to sensor 1713. Note that to detect substantial contact between the pick face 1700P and the fence 1510F, the bot controller 1220 may be configured to monitor a load on the drive unit 1531 (e.g., a rise in current, etc.). As will be appreciated, the sensor 1714 may be located at any suitable position relative to the load bed 1510 to detect substantial contact between the pick face 1700P and the fence 1510F. It will also be appreciated that the drive units 1531, 1532 may operate substantially simultaneously or independently to move the pick face in the directions of the arrows 1550, 1551 to substantially contact the first and second reference surfaces (e.g., either of the sides 1510S1, 1510S2 and the fence 1510F). In this manner, the pick face 1700P is repeatably placed in a predetermined position on the load bed 1510 when the pick face is in substantial contact with the first and second reference planes (which may be substantially perpendicular to one another).

[0037] To actively grip the pick face 1700P between the case unit contact member 1530 and the fence 1510F ( FIG. 11 , block 1104) during transport of the pick face on the bot 110, the case unit contact member 1530 may maintain substantial contact with the pick face 1700P and may operate in conjunction with the fence 1510F (e.g., FIG. 10 ). To grip the pick face 1700P, the bot 110 may move the case unit contact member a distance that depends on the depth D of the pick face 1700P, causing the case unit contact member to grip the pick face between the case unit contact member and the fence. Gripping the pick face 1700P in this manner not only prevents the pick face 1700P from becoming dislodged or falling off the load bed 1510 during transport of the pick face 1700P, but also substantially maintains the position of the pick face 1700P relative to the bot 110. It is noted that the pick face may be actively grasped by the bot 110 during transport of the pick face in any suitable manner.

[0038] The bot 110 may be instructed by the control server 120 to transport the pick face 1700P on the load bed 1510 to a predetermined position (e.g., a destination) within the storage and retrieval system 100. At the predetermined destination, the case unit contact member 1530 may be moved to release the grip on the pick face 1700P. In an embodiment, the bot controller 1220 may cause the drive unit 1532 to move the roller 1510R, thereby moving the pick face 1700P in the direction of the arrow 1551 a predetermined distance away from a first reference surface (e.g., one of the sides 1510S1 or 1510S2). This allows the pick face 1700P to be lifted from the load bed 1510 and transported from the bot without substantially contacting the side of the load bed 1510 (e.g., unobstructed movement of the pick face 1700P from the load bed). The bot controller 1220 may be configured to receive a signal from, for example, the sensor 1713 or obtain any other suitable information (such as information from the encoder of the drive unit 1532) to measure the distance between the pick face 1700P and the sides 1510S1 and 1510S2. When the measured distance is approximately equal to a predetermined distance (e.g., a distance stored in the memory of the bot or the control server 120), the bot controller 1220 may cause the drive unit 1532 to stop moving the pick face 1700P. After the pick face 1700P moves away from the sides 1510S1 and 1510S2, the bot 110 may cause the case unit contact member to press the pick face 1700P against the fence 1510F, thereby readjusting the position of the pick face 1700P relative to the fence 1510F so that all case units within the pick face substantially contact each other. The readjustment and compaction of the pick face position (e.g., moving the case unit together) may be monitored in any suitable manner, such as using any suitable sensor (such as those described above) and / or by monitoring the status of one or more bot drive motors, such as motors 1531, 1532.The distance between the pick face 1700P and the sides 1510S1, 1510S2 may be recorded by the controller 1220, and the position of the pick face 1700P relative to the fence 1510F may be readjusted so that the relative position between the pick face 1700P and the bot is maintained in a known relationship that allows the bot to place the pick face 1700P, for example, in a predetermined location on the storage shelf 600. The predetermined locations of the pick face and each case unit therein may be stored in any suitable location, such as in the memory of the control server 120, for use when retrieving the pick face from its respective location on the storage shelf.

[0039] To place the pick face 1700P in the desired position, the bot controller 1220 causes the fingers 1540 to lift the pick face 1700P from the rollers 1510R and above the stops 1510FM of the fence 1510F, extending the fingers 1540 laterally away from the bot 110. When the pick face 1700P is at its destination, e.g., above the storage shelf 600, the fingers 1540 are lowered between the stops 1510FM of the fence (e.g., into the slots 1510FS) and transported to the support surfaces 620H1, 620H2 of the storage shelf 600, e.g., having slats, to place the pick face 1700P on the shelf 600 (FIG. 11, block 1105).

[0040] 7A, 12, 13A, and 13B, the case unit contact member 1530 may be removably coupled to the movable member 1535 in any suitable manner for engagement therewith. Engagement between the case unit contact member 1530 and the movable member 1535 allows the case unit contact member 1530 and the movable member 1535 (and thus the arms / fingers of the robot) to move as a unit in the direction of arrow 1550, driven by a single axis drive to extend and retract the fingers 1540 in conjunction with the actuation of the case unit contact member 1530. Removable coupling between the movable member 1535 and the case unit contact member 1530 is effected passively by raising and lowering at least one finger 1540, such that coupling occurs when at least one of the fingers 1540 is raised, and disengages when the finger 1540 is in a substantially lowered position. For example, as described in U.S. Provisional Patent Application No. 61 / 423,220, entitled "BOT PAYLOAD ALIGNMENT AND SENSING," attorney docket number 1127P014263-US(-#1), which is already incorporated by reference herein (now U.S. Patent Application No. 13 / 327,040, filed December 15, 2011, attorney docket number 1127P014263-US(PAR)), it is noted that when the fingers are lowered (e.g., uncoupled), the case unit contact member 1530 is movable independently of the movable member 1535, for example, to adjust the position of or grip the pick face on the load bed.

[0041] Each mounting member 1671 may include any suitable protrusion that engages a complementary recess in the case unit contact member 1530 when the mounting member 1671 rises to lift the respective finger. As described above, the mounting member 1671 is attached to the movable member 1535 and is slidable relative to the movable member 1535 only in the direction of arrow 1673 (e.g., generally perpendicular to the direction of movement 1550 of the case unit contact member 1530), so that the engagement of the protrusion in the recess selectively couples the movable member 1535 to the case unit contact member 1530, such that when the case unit contact member is driven by the driver 1531 ( FIG. 9 ), the movable member 1535 is also driven to extend and retract the fingers 1540.

[0042] In an embodiment, the protrusions and recesses may be in the form of keys 3004 and keyholes 3002, as shown in FIG. 13B . However, it should be understood that in an embodiment, the protrusions and recesses may have any suitable configuration. Here, the keys 3004 may extend from a side of one or more mounting members 1671 facing the case unit contact members 1530, such that when the case unit contact members 1530 are in a retracted position (e.g., a position closest to the movable member 1535), the keys 3004 extend through the respective keyholes 3002 of the case unit contact members 1530. When one or more mounting members 1671 (e.g., fingers 1540) are lifted, the keys 3004 of the one or more mounting members 1671 move into the slots of the respective keyholes 3002, such that a portion of the keys 3004 protrudes through the slots of the keyholes and substantially engages the surface 1530S of the case unit contact members 1530. In one example, the keyhole and key may be positioned within a recess 1530R in the case unit contact member 1530 so as not to interfere with any pick faces that may substantially contact the case unit contact member 1530. Note that the case unit contact member 1530 may include a ridge or rib 1533 extending from one side of the case unit contact member 1530 to substantially prevent interference between the keyhole and key and any pick faces on the fingers 1540 or on the load bed 1510.

[0043] In an embodiment, the protrusions may be in the form of one or more pins 3000 extending from the mounting member 1671, and the recesses may be in the form of one or more slots 3001 disposed in the case unit contact member 1530. As shown in FIGS. 13A and 13B , when the case unit contact member 1530 is in a substantially retracted position, the one or more slots 3001 may be disposed adjacent to the one or more mounting members 1671. When the case unit contact member 1530 is in the retracted position, the slots 3001 are substantially aligned with the pins 3000 in the direction 1673, such that when the mounting member 1671 (e.g., fingers 1540) is lifted by the respective drivers 1672, the pins 3000 move into and engage the slots 3001. In an embodiment, at least one slot 3001 is positioned adjacent to ends 1530E1, 1530E2 of the case unit contact members 1530 such that only the attachment members 1671 of the outermost fingers 1540 can engage with the slot 3001 to couple the movable member 1535 and the case unit contact members 1530. Here, the pick face may be positioned on the load bed 1510 (FIG. 5) so that the pick face is aligned with at least one of the outermost fingers 1540 during transfer to and from the bot 110. Note that there may be slots positioned along the length of the case unit contact members so that any of the attachment members 1671 can couple the movable member 1535 and the case unit contact members 1530 when the respective fingers 1540 are raised.

[0044] As will be appreciated, the engagement of the pin 3000 and slot 3001 may be used in any suitable manner, either separately from or in conjunction with the engagement of the key 3004 and keyhole 3002. For example, the mounting member 1671 of the outermost finger 1540 may be configured with the pin 3000 to engage with the recess 3001 located adjacent the ends 1530E1, 1530E2 of the case unit contact member 1530, while the mounting member 1671 of the inner finger (located between the outermost fingers) may be configured with the key 3004 to engage with the keyhole 3002 located between the ends 1530E1, 1530E2 of the case unit contact member 1530. It is noted that in embodiments, the engagement between the case unit contact member 1530 and the movable member 1535 may be achieved in any suitable manner. It will also be appreciated that releasable coupling between the movable member 1535 (e.g., a bot transport arm) and the case unit contact member 1530 may be effected by lifting any suitable number of fingers 1540. For example, the coupling may be effected by lifting one of the outermost fingers, both of the outermost fingers, one of the inner fingers, multiple inner fingers, or any suitable combination of inner and outer fingers. Furthermore, the slots 3001 and keyholes 3002 may be configured to enable coupling between the movable member 1535 and the case unit contact member 1530 by only partially lifting one or more fingers 1540. For example, engagement of the slots and keyholes and coupling with the corresponding pins and keys may occur when the fingers are raised to a position for insertion into the storage shelf 600 under the pick face. The slots and keyholes may further be configured to allow the fingers 1540 to be further lifted (e.g., the keys and pins may be slidable within the engagements of the respective keyholes and slots), thereby allowing the pick face to be lifted from the storage shelf 600 and carried to the load bed 1510 of the bot 110.

[0045] 4A and 9, an exemplary operation of the bot 110 will now be described. The bot controller 1220 may move the bot to a predetermined pick face position, for example, on a storage rack 600 (or a multi-level vertical conveyor). The pick face position may include a pick face 1700P where each case unit 1700A, 1700B is positioned on the storage rack 600, such that the positions of the leading edge 1705 and trailing edge 1706 of case unit 1700A and the leading edge 1707 and trailing edge 1708 of case unit 1700B are known, for example, by the bot controller 1220 and / or the control server 120. While the pick face 1700P is shown as having two case units 1700A, 1700B, it is noted that the pick face may include any suitable number of case units. The bot controller 1220 may raise one or more fingers 1540 a predetermined distance (e.g., only partially to insert the fingers into the storage shelf 600 under the pick face 1700P), thereby coupling the movable member 1535 to the case unit contact member 1530. The one or more fingers 1540 may extend into the storage shelf slats under the case unit to be removed. The bot controller 1220 or any other suitable controller may be configured to determine the amount of arm extension so that the cantilevered tip of the raised finger 1540 underpick (removes from the bot along the axis of extension of the finger 1540) the farthest case unit to be transported to the bot 110. For example, if the bot 110 is instructed to retrieve only case 1700A, the finger 1540 may be extended into the storage rack so that the tip of the cantilevered finger 1540 is positioned a predetermined distance U (e.g., underpick) away from the trailing edge 1706 of the case unit 1700A.When the robot 110 is instructed to remove pick cases 1700A and 1700B, the fingers 1540 may be extended into the storage rack so that the tips of the cantilevered fingers 1540 are positioned a predetermined distance U from the trailing edge 1708 of the case unit 1700B. The under-pick U allows one or more cases to be removed without disturbing adjacent cases in the pick face. For example, case unit 1700A can be removed without disturbing case unit 1700B. For example, in a manner substantially similar to that described in U.S. Provisional Patent Application No. 61 / 423,220, entitled "BOT PAYLOAD ALIGNMENT AND SENSING" and attorney docket number 1127P014263-US(-#1), already incorporated herein by reference (now U.S. Patent Application No. 13 / 327,040, filed December 15, 2011, and attorney docket number 1127P014263-US(PAR)), once underneath the case unit to be removed (for illustrative purposes only, case unit 1700A), the fingers are raised to remove case unit 1700A from the shelf and the fingers are retracted in the direction of arrow 1550, thereby transporting case unit 1700B to the bot payload area.

[0046] When the case unit 1700A is carried onto the load bed 1510 of the robot 110, a clearance C is required between the edge 1706 of the case unit 1700A and the fence 1510F to prevent the case unit 1700A from hitting the fence 1510F or interfering with the case protrusion sensor 1703 when the case unit is lowered onto the load bed 1510. The length of the clearance C may be determined by subtracting both the underpick distance U and the finger length L from the depth D of the load bed 1510 (e.g., C = DLU). In one example, the underpick distance U may be a predetermined distance, such as approximately 9 mm, or any other suitable distance, and the depth D of the load bed 1510 may be a constant value. Therefore, to increase the length of the clearance C between the edge 1706 of the case unit 1700A and the fence 1510F, the length L of the finger 1540 must be decreased. Alternatively, if the spacing C is a predetermined distance and the depth D of the load bed 1510 is constant, then to increase the underpick distance U (e.g., U=DLC), the finger length L must be decreased. As will be appreciated, the underpick U and spacing C may be adjusted without changing the finger length L, but the underpick U and spacing C cannot be changed independently without changing the arm length L.

[0047] As noted above, with reference to Figures 4B, 4C, 5, 7A, 12, 15A, 15B and 16, the case unit contact member 1530 may be movably mounted at least partially within the loading area where the case unit contact member is removably coupled to the movable member 1535 to extend and retract the transfer arm 1540A in the direction of arrow 1550, for example, in the manner described in U.S. Provisional Patent Application No. 61 / 423,365, entitled "AUTOMATED BOT WITH TRANSFER ARM," attorney docket number 1127P014264-US(-#1) (now U.S. Patent Application No. 13 / 326,952, filed December 15, 2011, attorney docket number 1127P014264-US(PAR)), which is already incorporated by reference herein. During operation, the bot 110 retrieves or places a pick face on the multi-level vertical conveyors 150A, 150B, so that the only item on the conveyor shelf 720 (pick face 8003 in this example) may be the one retrieved or placed by the bot 110. Meanwhile, when the bot 110 retrieves or places pick face 8003 on the storage shelf 600, other pick faces 8001, 8002 may be located adjacent to the position 8000 from which the bot retrieves or places it. As will be appreciated, the controller 1220 of the bot 110 may be configured to handle the transport of items from / to the conveyors 150A, 150B, rather than the transport of items from / to the storage shelf 600. For example, when transferring an item to / from conveyors 150A, 150B, the bot may lift all of its fingers 1540, for example, above fence stop member 1510FM, to transfer the pick face. Because the only item on conveyor shelf 720 is pick face 8003 being transferred to / from bot 110, the lifting and extension of all fingers 1540 does not interfere with other items on conveyors 150A, 150B.Additionally, the lifting and extension of all fingers 1540 substantially ensures distributed support of pick face 8003 being removed by fingers 1540 from inbound conveyor 150A, and the position of the pick face on conveyor shelf 720 may not be known. For example, when transporting a pick face from / to storage shelf 600 at pick face position 8000, lifting all fingers 1540 to extend toward storage shelf 600 may result in contact with pick faces 8001, 8002 adjacent to position 8000. As can be appreciated, only one finger 1540U (FIG. 7A) supporting pick face 8003 (pick face 1700P in FIG. 7A) being transported to shelf 600 may be raised, while the remaining fingers 1540L remain in a substantially lowered position, so that when pick face 8003 is transported to pick face position 8000, the fingers 1540L not supporting pick face 8003 are inserted into shelf 600 below (and not in contact with) pick faces 8001, 8002. Note that in an embodiment, the storage shelves and / or conveyor shelves may be configured such that extension of transport arm 1540A may be treated similarly to transport of case units between the bot and both the storage shelves and the multi-level vertical conveyor.

[0048] The lift position or height of each finger 1540 can be measured in any suitable manner. Referring to FIG. 15A , a lift position sensor may be installed along the lift axis of one or more fingers 1540 to measure / record the position of the one or more fingers 1540. The lift position sensor may include an alignment device 7000 and one or more detection devices 7001A-7001E. In one example, the alignment device 7000 may be attached to the mounting member 1671, and one or more detection devices 7001A-7001E may be attached to the movable member 1535. In embodiments, the alignment device and detection devices may be beam (or optical) sensors, capacitive or inductive sensors, or any other suitable type of sensor that allows for detection of, for example, the movement of the mounting member 1671 relative to the movable member 1535. By way of example only, the alignment device 7000 may be a reflective flag in the case of an optical sensor, or a magnetic / electrical member in the case of a capacitive or inductive sensor. It is noted that, in embodiments, the alignment device may be any suitable device capable of being detected by the detection device. The detection devices 7001A-7001E may be spaced apart along the movable member to divide the travel distance over which the driver 1672 drives the fingers 1540. The controller 1220 may be connected to one or more alignment devices 7000 and detection devices 7001A-7001E and configured to receive signals from these devices, for example, as a signal from a sensor transition from one detector to the next, to detect the position of each finger 1540. It is understood that, while in this example four sections of travel are defined by five detectors 7001A-7001E, it is noted that any suitable number of detectors may be used to define any suitable number of sections of travel (e.g., two detectors may be used to define one section of travel that includes the full lift stroke of a finger, but additional detectors may be added to provide stops between the upper and lower limits of the full lift stroke).It will also be understood that the signal received by the controller may have a tooth-shaped or sinusoidal profile, for example, that is high when the alignment device 7000 is adjacent to one of the detection devices 7001A-7001E and low when the alignment device 7000 is between adjacent detection devices 7001A-7001E.

[0049] In one example, when the finger 1540 selected for activation is substantially in its lowest position (thereby positioning the finger below the load bed 1510), the alignment device 7000 may be positioned adjacent to the detector 7001E. For example, when the driver 1672 is activated to move the selected finger in the direction of arrow 1673 and the alignment device 7000 is adjacent to the detector 7001E, a high signal may be sent from the detector 7001E to the controller 1220 to identify the selected finger 1540 as being in its lowest position (while the other detectors 7001A-7001D are providing low signals). When the controller 1220 receives the signal from the detector 7001E, the controller 1220 may send a command to the driver 1672 for the selected finger 1540, causing the driver 1672 to stop so that the finger 1540 is substantially in its lowest position. Similarly, for example, when the driver 1672 is activated to move the finger in the direction of arrow 1673 and the alignment device 7000 is adjacent the detector 7001A (e.g., the finger is in substantially its highest position so that the finger is above the fence stop member 1510FM for transporting a pick face to and from the load bed 1510), a high signal may be sent from the detector 7001A to the controller 1220 to identify the finger 1540 as being in its highest position (while the other detectors 7001B-7001E are providing low signals). When the controller 1220 receives the signal from the detector 7001A, the controller 1220 may send a command to the driver 1672 for the selected finger 1540, causing the driver 1672 to stop so that the finger 1540 is in substantially its highest position. As will be appreciated, other detectors 7001B-7001D may be placed between detectors 7001A, 7001E to provide other heights at which the fingers may be stopped in the manner described above.

[0050] 15B, one detector 7001 may be mounted on movable member 1535, and one or more alignment members 7000A-7000E may be mounted on mounting member 1671 adjacent one or more fingers 1540. A signal may be sent by detector 7001 to controller 1220 when a selected finger 1540 is moved in the direction of arrow 1673 and a respective alignment member 7000A-7000E is adjacent detector 7001. The controller 1220 may be configured to count or record which of the alignment members 7000A-7000E are adjacent the detector 7001 (e.g., in the manner described above with respect to FIG. 15A ) and may be configured to send appropriate commands to the driver 1672 to stop the fingers 1540 at a desired predetermined position (e.g., when the fingers are in their highest position, when the fingers are in their lowest position below the load bed, or any suitable position in between, for transporting pick faces to and from the load bed). It is noted that any suitable combination and type of alignment members and detectors may be attached to and used in any suitable portion of the robot 110 to measure the lift height of the fingers 1540.

[0051] It is also noted that the position of each finger in the direction of arrow 1673 along the lift axis may be determined from driver feedback. For example, each driver 1672 may be configured to send a signal to controller 1220 to count the number of rotations (or a fraction thereof) made by the driver. Controller 1220 may also be configured to record the number of pulses used to move stepper motor driver 1672, for example. As will be appreciated, any suitable motor feedback or other information may be used to determine the lift position of each finger 1540.

[0052] 1, 17A, and 17B, the bot 110 may include any suitable inertial sensor 899 to detect, for example, tilt α of the bot 110 from horizontal, such as occurs when the bot is positioned at a transfer station on the transport deck 130B. The inertial sensor 899 may stop the multi-level vertical conveyors 150A, 150B when the bot contacts the conveyor, causing the bot 110 to tilt beyond a predetermined angle, or when the case carried by the bot contacts the conveyor, causing the bot 110 to tilt beyond a predetermined angle (or vice versa). FIG. 17A illustrates contact between the bot transport arm 1540A and the shelf 720 of the inbound multi-level vertical conveyor 150A (for illustrative purposes only, due to misalignment between the fingers of the bot arm and the fingers of the conveyor shelf), such that movement of the shelf 720 in the direction of arrow 998 causes the bot to tilt. Another example that may cause the bot to tilt is when the bot arm 1540A is extended too quickly and a case on either the bot arm or the conveyor shelf prevents the bot arm's fingers from interlocking with the conveyor shelf. The inertial sensor 899 may detect the tilt α and send a signal to, for example, the bot controller 1220. The bot controller 1220 may send a corresponding signal to the control server 120, which is configured to stop operation of the conveyor 150A. Note that the inertial sensor 899 may also be configured to send a signal directly to the control server 120. The control server 120 may be configured to communicate with the bot 110 and record the position of the bot 110 in the storage and retrieval system 100 so that a conveyor 150A associated with a tilted bot 110 can be identified and stopped (e.g., as described in U.S. patent application Ser. No. 12 / 757,337, entitled "CONTROL SYSTEM FOR STORAGE AND RETRIEVAL SYSTEMS," already incorporated by reference herein). In response to the inertial sensor 899 detecting the tilt α of the bot 110, the bot controller 1220 may retract the transport arm 1540A, thereby allowing the bot 110 to return to a horizontal orientation without contacting the conveyor 150A.17B illustrates contact between the bot transport arm 1540A and the shelf 720 of the outgoing multi-level vertical conveyor 150B, such that movement of the shelf 720 in the direction of arrow 998 causes the bot to tilt in the opposite direction to that of FIG. 17A. In substantially the same manner as described above, stopping of the outgoing multi-level vertical conveyor 150B and retraction of the transport arm 1540A may occur, thereby allowing the bot 110 to avoid contact with the outgoing multi-level vertical conveyor 150B. The bot 110 may be configured to time out (e.g., stop operation) or allow manual intervention when it detects that the tilt α of the bot 110 exceeds a predetermined amount of tilt, thereby allowing any appropriate corrective action to be taken, such as retracting the transport arm as described above.

[0053] In a first aspect of the disclosed embodiments, an autonomous transport robot for transporting a load is provided, the autonomous transport robot including a load bed having at least one reference surface and at least one load alignment device configured to place a load on the load bed in substantial contact with the at least one reference surface to place the load at a predetermined position on the load bed.

[0054] In accordance with a first aspect of the disclosed embodiment, the at least one reference surface includes first and second reference surfaces arranged substantially perpendicular to each other, and one of the first and second reference surfaces is substantially parallel to a longitudinal axis of the autonomous transport robot.

[0055] In accordance with a first aspect of the disclosed embodiment, the autonomous transport robot includes a retaining fence disposed at an opening in the load bed, and the autonomous transport robot further includes a driven pusher bar movably disposed at least partially above the load bed, the retaining fence and the driven pusher bar configured to actively grasp the load during transport of the load on the autonomous transport robot.

[0056] In accordance with a first aspect of the disclosed embodiment, the autonomous transport robot further comprises at least one sensor for detecting at least one dimension of the payload.

[0057] According to a first sub-aspect of the first aspect of the disclosed embodiment, the autonomous transport robot further includes a retractable actuator for transporting a load between a load holding area and the load bed, and the load bed includes a guide surface configured to guide the load into the load bed area during transport of the load onto the autonomous transport robot.

[0058] According to a first sub-aspect of a first aspect of the disclosed embodiment, the actuator is configured to be raised from below the load bed to a position at least partially above a retaining fence positioned at an opening in the load bed, the retaining fence extending above the load bed and configured to at least partially retain a load on the load bed.

[0059] In accordance with a first aspect of the disclosed embodiment, the at least one alignment device includes a first alignment device configured to move the load in a first direction to substantially contact a first reference surface, and a second alignment device configured to move the load in a second direction generally perpendicular to the first direction to contact a second reference surface.

[0060] In accordance with a first aspect of the disclosed embodiment, the first aligner includes a driven roller that forms a load support surface for the load bed.

[0061] In accordance with a first aspect of the disclosed embodiment, the second alignment device includes a driven pusher bar.

[0062] In accordance with a first aspect of the disclosed embodiment, the autonomous transport robot includes at least one sensor that detects substantial contact between the payload and at least one of the first and second reference surfaces.

[0063] In accordance with a first aspect of the disclosed embodiment, the first alignment device is configured to move the load a predetermined distance away from each of the reference surfaces when the load is transported from the load bed, and the second alignment device is configured to realign the load relative to the second reference surface.

[0064] According to a second aspect of the disclosed embodiment, an autonomous transport robot for transporting a load within a storage and retrieval system is provided, the autonomous transport robot including: a load bed having an opening; an actuator for transporting a load to and from the load bed at least partially through the opening; at least one sensor disposed adjacent the opening for detecting first and second edges of the load; and a controller configured to measure dimensions of the load based at least in part on the detection of the first and second edges of the load and to compare the measured dimensions of the load to predetermined dimensions of the load.

[0065] According to a first sub-aspect of the second aspect of the disclosed embodiment, the controller is configured to signal a fault if the detected dimension and the predetermined dimension do not substantially match.

[0066] According to a first sub-aspect of the second aspect of the disclosed embodiment, the controller is further configured to cause the effector to return the load to the load holding area from which it was removed if the detected dimension does not substantially match the predetermined dimension.

[0067] According to a first subaspect of the second aspect of the disclosed embodiment, the controller is further configured to verify a position of the autonomous transport robot within the storage and retrieval system if the detected dimension does not substantially match the predetermined dimension.

[0068] According to a second sub-aspect of the second aspect of the disclosed embodiment, the at least one sensor includes a sensor that detects another edge of the load that is substantially intersecting with the first and second edges, and the controller is configured to measure another dimension of the load that is substantially intersecting with the dimension based at least in part on the detection of the other edge.

[0069] According to a second sub-aspect of the second aspect of the disclosed embodiment, the autonomous transport robot further includes a load alignment device that moves the load on the load bed in a direction substantially intersecting the direction in which the load is loaded onto the load bed, the load alignment device being configured to facilitate, at least in part, detection of another dimension.

[0070] According to a third aspect of the disclosed embodiment, there is provided an autonomous guided vehicle including: a load bed; and a transport arm disposed on the load bed and configured to extend along a first axis to transport pick faces to and from the load bed, the transport arm including fingers independently movable relative to one another along a second axis generally perpendicular to the first axis to retrieve and place pick faces.

[0071] In accordance with a third aspect of the disclosed embodiment, the autonomous guided vehicle further includes a drive for each finger, the drive configured to selectively move the respective finger along a second axis.

[0072] In accordance with a first subaspect of a third aspect of the disclosed embodiment, the autonomous guided vehicle further includes a movable member to which the fingers are cantilevered from the movable member for unified movement along a first axis.

[0073] According to a first subaspect of the third aspect of the disclosed embodiment, the autonomous guided vehicle further includes a driven member configured to be selectively coupled to the movable member to move the transport arm along a first axis, and further wherein the one or more fingers have protrusions and the driven member has at least one corresponding recess, and when the one or more fingers are raised, the protrusions engage the recesses to couple the movable member and the driven member.

[0074] According to a fourth aspect of the disclosed embodiment, there is provided an autonomous guided vehicle including a driven member, a movable member, and a positionable coupling configured to selectively couple the movable member and the driven member, the positionable coupling being capable of coupling and disengaging such that, when released, the driven member is movable along a first axis independently from the movable member, and when coupled, the driven member and the movable member move together along the first axis.

[0075] According to a fourth aspect of the disclosed embodiment, the autonomous transport vehicle further includes a load bed, wherein the driven member is configured to at least orient the case unit on the load bed, and the movable member transports a portion of the case unit to and from the load bed.

[0076] According to a first sub-aspect of the fourth aspect of the disclosed embodiment, the movable member includes fingers movable along a second axis, the second axis being generally perpendicular to the first axis, and the one or more fingers engage the driven member to couple the movable member to the driven member.

[0077] According to a first sub-aspect of the fourth aspect of the disclosed embodiment, the autonomous transport vehicle further includes a controller configured to determine an amount of movement of the finger along a first axis such that the cantilever tip of the finger is positioned at a distance from the distal end of the case unit to be removed so as not to extend beyond the edge of the case unit.

[0078] In accordance with a fourth aspect of the disclosed embodiment, the movable member includes at least one side blade configured to substantially contact one side of the one or more case units to align the one or more case units for transport to the storage shelf.

[0079] According to a fifth aspect of the disclosed embodiment, there is provided an autonomous transport vehicle including: a frame including a transport area; a drive system; and a transport arm disposed in the transport area and having fingers connected to the frame via the drive system, the drive system configured to move the fingers together along a first axis and move each finger independently relative to other fingers of the transport arm along a second axis generally perpendicular to the first axis.

[0080] In accordance with a fifth aspect of the disclosed embodiment, the drive system includes a single axis drive common to all of the fingers and configured to move the fingers along a first axis.

[0081] In accordance with a fifth aspect of the disclosed embodiment, the drive system includes a linear drive for each finger, each linear drive configured to move each finger individually along the second axis independent of the other drives for that finger.

[0082] In accordance with a fifth aspect of the disclosed embodiment, the drive system includes a linear drive selectively coupled to each finger, the linear drive configured to move the one or more fingers along the second axis.

[0083] According to a first sub-aspect of the fifth aspect of the disclosed embodiment, movement of the finger along the second axis couples the finger to the drive system for movement along the first axis.

[0084] According to a first sub-aspect of the fifth aspect of the disclosed embodiment, the autonomous guided vehicle further includes a movable member configured to engage a payload of the autonomous guided vehicle, and the drive system is configured to move the one or more fingers along the first axis by moving the one or more fingers along the second axis to selectively couple the one or more fingers to the movable member and drive the movable member along the first axis.

[0085] According to a fifth aspect of the disclosed embodiment, the fingers are cantilevered from the frame.

[0086] According to a sixth aspect of the disclosed embodiment, an autonomous guided vehicle is provided. The autonomous guided vehicle includes a transport arm including at least one finger and a movable finger support member, where the at least one finger is movably coupled to the finger support member, such that the finger support member moves in a first direction and the at least one finger moves relative to the finger support member in a second direction generally perpendicular to the first direction. The autonomous guided vehicle includes at least one sensor configured to detect movement of the at least one finger, the at least one sensor having an alignment member and a detection member, one of the alignment member and the detection member attached to each of the at least one finger so as to move together with the at least one finger, and the other of the alignment member and the detection member not moving relative to the at least one finger. The autonomous guided vehicle includes a controller in communication with the at least one sensor, where the controller is configured to determine a position of the at least one finger along the second direction based on a proximity of the alignment member to the detection member.

[0087] According to a sixth aspect of the disclosed embodiment, the other of the alignment member and the detection member is mounted on a movable finger support.

[0088] According to a sixth aspect of the disclosed embodiment, the at least one sensor is an optical sensor, a capacitive sensor, or an inductive sensor.

[0089] According to a sixth aspect of the disclosed embodiment, the alignment member includes a reflective flag or a magnetic source.

[0090] In accordance with a sixth aspect of the disclosed embodiment, the autonomous guided vehicle includes a drive device for each of the at least one finger, and the controller is configured to actuate the drive device for each of the at least one finger, thereby causing each of the at least one finger to move substantially in unison along the second direction.

[0091] According to a sixth aspect of the disclosed embodiment, the drive for each of the at least one finger includes a stepper motor.

[0092] In accordance with a sixth aspect of the disclosed embodiment, the controller is configured to selectively move each of the at least one fingers along a second direction in response to a size of a pick face carried by the autonomous guided vehicle.

[0093] According to a sixth aspect of the disclosed embodiment, the autonomous guided vehicle includes an inertial sensor coupled to the controller, the inertial sensor configured to detect tilt of the autonomous guided vehicle relative to a horizontal plane.

[0094] According to a seventh aspect of the disclosed embodiment, there is provided a storage and retrieval system having at least one multi-level vertical conveyor and at least one autonomous transport vehicle, the at least one autonomous transport vehicle including a controller and an inertial sensor configured to detect tilt of the autonomous transport vehicle when the autonomous transport vehicle contacts a moving shelf of the at least one multi-level vertical conveyor, and when the tilt exceeds a predetermined tilt amount, the controller is configured to at least partially stop operation of the multi-level vertical conveyor.

[0095] In accordance with a seventh aspect of the disclosed embodiment, the storage and retrieval system further includes a control server in communication with the controller of the autonomous guided vehicle, the control server configured to receive a signal from the controller regarding an inclination of the autonomous guided vehicle and configured to stop operation of the multi-level vertical conveyor.

[0096] In accordance with a seventh aspect of the disclosed embodiment, the autonomous transport vehicle further includes a transport arm that interacts with a moving shelf of the multi-level vertical conveyor, and the controller is configured to substantially retract the transport arm when a tilt exceeding a predetermined amount of tilt is detected.

[0097] According to an eighth aspect of the exemplary embodiment, there is provided an autonomous guided vehicle including a transport arm having a finger support member and a plurality of movable fingers coupled to the finger support member, the autonomous guided vehicle further including a drive unit coupled to each of the plurality of fingers for independently moving each finger relative to the finger support member, and a controller connected to each drive unit for selectively actuating the drive units to start or stop the selected drive units in unison with a single start or stop command from the controller.

[0098] According to an eighth aspect of the disclosed embodiment, each drive device includes a stepper motor and a linear actuator, and the stepper motor is coupled to each of the plurality of fingers via the linear actuator.

[0099] According to an eighth aspect of the disclosed embodiment, the linear actuator comprises a ball screw.

[0100] In accordance with an eighth aspect of the disclosed embodiment, one or more of the plurality of fingers includes a sensor coupled to the controller, the sensor configured to send a signal to the controller indicating that the one or more of the plurality of fingers is in a predetermined position relative to the finger support member.

[0101] According to an eighth aspect of the disclosed embodiment, the controller is configured to stop operation of one or more of the plurality of fingers when the controller receives a signal indicating that one or more of the plurality of fingers is in a predetermined position relative to the finger support member.

[0102] It should be understood that the exemplary embodiments disclosed herein can be used individually or in any suitable combination. It should also be understood that the foregoing description is merely illustrative of embodiments. Various changes and modifications may be devised by those skilled in the art without departing from the embodiments. Accordingly, the present embodiments are intended to embrace all such changes, modifications, and variations that fall within the scope of the appended claims.

Claims

1. a finger support member configured to be movable along an extension axis; and a transfer arm having a plurality of fingers movably connected to the finger support member; a drive device coupled to each of the plurality of fingers, the drive device having a drive motor for independently moving each finger relative to the finger support member in a lift direction perpendicular to the extension axis; a controller connected to each of the drives for selectively operating the drives, the controller in response to a single start command from the controller simultaneously starting the drives selected by that connection, and the controller in response to a single stop command from the controller simultaneously disabling the drives selected by that connection; An autonomous transport vehicle comprising:

2. The autonomous guided vehicle of claim 1 , wherein each of the drive devices includes a stepper motor and a linear actuator, and the stepper motor is coupled to each of the plurality of fingers via the linear actuator.

3. The autonomous guided vehicle of claim 2 , wherein the linear actuator comprises a ball screw.

4. 2. The autonomous guided vehicle of claim 1, wherein one or more of the plurality of fingers includes a sensor connected to the controller, the sensor configured to send a signal to the controller indicating that one or more of the plurality of fingers is in a predetermined position relative to the finger support member.

5. 2. The autonomous guided vehicle of claim 1, wherein the controller is configured to stop operation of one or more of the plurality of fingers when the controller receives a signal indicating that one or more of the plurality of fingers is in a predetermined position relative to the finger support member.

6. 1. A method for operating an automated storage and retrieval system, comprising: An autonomous guided vehicle is provided having a transport arm including at least one finger and a movable finger support member, the at least one finger being movably coupled to the finger support member; moving the finger support member in a first direction relative to a reference frame of the autonomous guided vehicle, and linearly moving at least one finger relative to the finger support member in a second direction substantially perpendicular to the first direction in both the reference frame of the autonomous guided vehicle and a surface on which the autonomous guided vehicle travels; detecting, with at least one sensor, indexed movement of the at least one finger in a second direction relative to the movable finger support member, the at least one sensor including an alignment member and a detection member, one of the alignment member and the detection member attached to each of the at least one finger so as to be linearly movable with and by the respective movement of the at least one finger, the other of the alignment member and the detection member being stationary with respect to the at least one finger, wherein a relative position between the alignment member and the detection member defines two or more indexed positions of the at least one finger; and The method further comprising determining, by a controller in communication with the at least one sensor, a position of the at least one finger along a second direction relative to the movable finger support member based on a proximity of the alignment member to the detection member.

7. The method of claim 6 , wherein the other of the alignment member and the detection member is attached to the movable finger support member.

8. The method of claim 6 , wherein the at least one sensor is an optical, capacitive, or inductive sensor.

9. The method of claim 6, wherein the alignment member comprises a reflective flag or a magnetic source.

10. providing the autonomous guided vehicle with a drive unit corresponding to each of the at least one finger; The method of claim 6 , further comprising the step of operating, with the controller, a drive for each of the at least one finger such that each of the at least one finger moves substantially in unison along the second direction.

11. The method of claim 6 , wherein the drive for each of the at least one finger comprises a stepper motor.

12. further providing the autonomous guided vehicle with an inertial sensor coupled to the controller; The method of claim 6 , further comprising detecting, with the inertial sensor, a tilt of the autonomous guided vehicle relative to a horizontal plane.

13. 1. A method of operating an automated storage and retrieval system, comprising: An autonomous guided vehicle is provided having a transport arm including at least one finger and a movable finger support member, the at least one finger being movably coupled to the finger support member; moving the finger support member in a first direction and moving the at least one finger relative to the finger support member in a second direction substantially perpendicular to the first direction; detecting movement of the at least one finger with at least one sensor, the at least one sensor having an alignment member and a detection member, one of the alignment member and the detection member attached to each of the at least one finger so as to be movable with the respective one of the at least one finger, and the other of the alignment member and the detection member being stationary relative to the at least one finger; determining, with a controller in communication with the at least one sensor, a position of the at least one finger along the second direction based on a proximity of the alignment member to the detection member; The method further comprising: selectively moving, by the controller, each of the at least one fingers along a second direction in response to a size of a pick face carried by the autonomous guided vehicle.

14. 14. The method of claim 13, wherein the at least one sensor includes an alignment member and a detection member, one of the alignment member and the detection member attached to each of the at least one finger and the other of the alignment member and the detection member attached to the movable finger support member.

15. The method of claim 13 , wherein the alignment member comprises a reflective flag or a magnetic source.

16. The method of claim 13 , wherein the at least one sensor is an optical, capacitive, or inductive sensor.

17. providing the autonomous guided vehicle with a drive unit corresponding to each of the at least one finger; The method of claim 13 , further comprising the step of operating, with the controller, a driver for each of the at least one finger such that each of the at least one finger moves substantially in unison along the second direction.

18. 20. The method of claim 17, wherein the driver for each of the at least one finger includes a stepper motor.

19. providing the autonomous guided vehicle with an inertial sensor coupled to the controller; The method of claim 13 , further comprising detecting, with the inertial sensor, a tilt of the autonomous guided vehicle relative to a horizontal plane.

20. 1. A method of operating an automated storage and retrieval system, comprising: An autonomous guided vehicle is provided having a transport arm including at least one finger and a movable finger support member, the at least one finger being movably coupled to the finger support member; moving the finger support member in a first direction, linearly moving at least one finger relative to the finger support member in a second direction substantially perpendicular to both the first direction and a surface on which the autonomous guided vehicle travels, and detecting indexed movement of the at least one finger with at least one sensor, the at least one sensor having an alignment member and a detection member, one of the alignment member and the detection member attached to each of the at least one finger so as to be linearly movable with and due to the respective movement of the at least one finger, the other of the alignment member and the detection member being fixed with respect to the at least one finger, and a relative position between the alignment member and the detection member defining two or more indexed positions of the at least one finger; and a controller in communication with the at least one sensor determining a position of the at least one finger along the second direction based on a proximity of the alignment member to the detection member; The method wherein the other of the alignment member and the detection member is attached to a movable finger support member.

21. 21. The method of claim 20, wherein the at least one sensor is an optical, capacitive, or inductive sensor.

22. The method of claim 20 , wherein the alignment member comprises a reflective flag or a magnetic source.

23. providing the autonomous guided vehicle with a drive for each of the at least one finger; and 21. The method of claim 20, further comprising the step of: actuating, with the controller, a driver for each of the at least one finger such that each of the at least one finger moves substantially in unison along the second direction.

24. 21. The method of claim 20, further comprising selectively moving, with the controller, each of the at least one finger along the second direction in response to a size of a pick face carried by the autonomous guided vehicle.

25. providing the autonomous guided vehicle with an inertial sensor coupled to the controller; and The method of claim 20 , further comprising detecting, with the inertial sensor, a tilt of the autonomous guided vehicle relative to a horizontal plane.

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