Systems and methods using mobile robots to assist other mobile robots

Abstract

There are provided systems and methods that may involve recovery mobile robots assisting incapacitated mobile robots at a facility. In one form, the system may include a facility with pathways for movement by mobile robots. The system may further include a recovery mobile robot with a locomotion system, a body, and one or both of a towing attachment or an extendable lift mechanism. In other forms, the recovery mobile robot may include a power supply, a locomotion system, a body, and a power connector for transferring charge to an incapacitated mobile robot. Methods of recovery and assistance are also provided.

Description

SYSTEMS AND METHODS USINGMOBILE ROBOTS TO ASSIST OTHER MOBILE ROBOTSCross-Reference To Related Applications

[0001] This application claims the benefit of and priority to U.S. Application No. 63 / 609,757 filed December 13, 2023, which is incorporated herein by reference in its entirety.Technical Field

[0002] This invention relates generally to mobile robots, and more particularly, to mobile robots that assist incapacitated mobile robots at a facility.Background

[0003] Automated storage and retrieval systems (ASRS) are being used increasingly in the context of fulfilling merchandise orders. In some forms, these systems may include mobile robots that move about a storage structure at an order fulfillment facility to pick and transfer containers and items. In some forms, mobile robots may travel along horizontal and vertical pathways in the facility.

[0004] Sometimes, during movement about the facility, mobile robots may become incapacitated or non-functional. In these circumstances, there may be a need to recover or assist these incapacitated or non-functional mobile robots. In one aspect, it would be desirable to use other mobile robots to assist or recover incapacitated or non-functional mobile robots without requiring a system stoppage and / or without requiring a technician to enter the system.Brief Description of the Drawings

[0005] Disclosed herein are embodiments of systems, apparatuses and methods involving recovery mobile robots, such as may be used at automated storage and retrieval systems. This description includes drawings, wherein:

[0006] FIG. 1A is a partial perspective view of an automated storage and retrieval system in accordance with some embodiments;

[0007] FIG. IB is a partial perspective view of the automated storage and retrieval system of FIG. 1 A in accordance with some embodiments;

[0008] FIG. 2A is a schematic view of a mobile robot assistance system in accordance with some embodiments;

[0009] FIG. 2B is a perspective view of a recovery mobile robot in accordance with some embodiments;

[0010] FIG. 2C is a perspective view of the recovery mobile robot of FIG. 2B in accordance with some embodiments;

[0011] FIG. 3 is a perspective view of a recovery mobile robot with a towing attachment in accordance with some embodiments;

[0012] FIG. 4 is a perspective view of the recovery mobile robot with a towing attachment of FIG. 3 in accordance with some embodiments;

[0013] FIG. 5 is a side view of the recovery mobile robot with a towing attachment of FIG. 3 in accordance with some embodiments;

[0014] FIG. 6 is a side view of the recovery mobile robot with a towing attachment of FIG. 3 in accordance with some embodiments;

[0015] FIG. 7 is a side view of the recovery mobile robot with a towing attachment of FIG. 3 in accordance with some embodiments;

[0016] FIG. 8 is a side view of the recovery mobile robot with a towing attachment of FIG. 3 in accordance with some embodiments;

[0017] FIG. 9 is a side view of a recovery mobile robot with a towing attachment in accordance with some embodiments;

[0018] FIG. 10 is a partial perspective view of the recovery mobile robot with a towing attachment of FIG. 9 in accordance with some embodiments;

[0019] FIG. 11 is a partial exploded view of the recovery mobile robot with a towing attachment of FIG. 9 in accordance with some embodiments;

[0020] FIG. 12 is a side view of the recovery mobile robot with a towing attachment of FIG. 9 in accordance with some embodiments;

[0021] FIG. 13 is a partial perspective view of a recovery mobile robot with a towing attachment in accordance with some embodiments;

[0022] FIG. 14 is a side view of the recovery mobile robot with a towing attachment of FIG. 13 in accordance with some embodiments;

[0023] FIG. 15 is a side view of a recovery mobile robot with maneuvering arms in accordance with some embodiments;

[0024] FIG. 16 is a perspective view of the recovery mobile robot with maneuvering arms of FIG. 15 in accordance with some embodiments;

[0025] FIG. 17 is a side view of the recovery mobile robot with maneuvering arms of FIG. 15 in accordance with some embodiments;

[0026] FIG. 18 is a side view of the recovery mobile robot with maneuvering arms of FIG. 15 in accordance with some embodiments;

[0027] FIG. 19 is a schematic view of a recovery mobile robot with a lift mechanism in accordance with some embodiments;

[0028] FIG. 20 is a schematic view of the recovery mobile robot with lift mechanism of FIG. 19 in accordance with some embodiments;

[0029] FIG. 21 is a flow diagram of a recovery mobile robot assisting or recovering incapacitated mobile robots in accordance with some embodiments;

[0030] FIG. 22 is a schematic view of a mobile robot assistance system in accordance with some embodiments;

[0031] FIG. 23 is a perspective view of a recovery mobile robot in accordance with some embodiments;

[0032] FIG. 24 is a perspective view of the recovery mobile robot of FIG. 23 in accordance with some embodiments;

[0033] FIG. 25 is a side view of the recovery mobile robot of FIG. 23 in accordance with some embodiments;

[0034] FIG. 26 is a perspective view of the recovery mobile robot of FIG. 23 in accordance with some embodiments;

[0035] FIG. 27 is a perspective view of the recovery mobile robot of FIG. 23 in accordance with some embodiments; and

[0036] FIG. 28 is a flow diagram of a recovery mobile robot assisting or recovering incapacitated mobile robots in accordance with some embodiments.

[0037] Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and / or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and / or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.Detailed Description

[0038] The following description is not to be taken in a limiting sense but is made merely for the purpose of describing the general principles of exemplary embodiments. Reference throughout this specification to “one form,” “one embodiment,” “an embodiment,” “some embodiments”, “an implementation”, “some implementations”, “some applications”, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” “in some embodiments”, “in some implementations”, and similar language throughout this specification do not all refer to the same embodiment.

[0039] The terms “top” and “bottom,” “upper” and “lower” and “vertical” and “horizontal as may be used herein are by way of example and illustrative purposes only and are not meant to limit the description of the embodiments inasmuch as the referenced item can be exchanged in position and orientation. Also, as used herein, the terms "substantially" and / or "about" mean that the specified dimension or parameter may be varied within an acceptable manufacturing tolerance for a given application.

[0040] Generally speaking, pursuant to various embodiments, systems, apparatuses and methods are provided herein using mobile robots to assist other mobile robots. In one form, the system includes a facility with a plurality of pathways configured for movement by a plurality of mobile robots therealong, the facility including a plurality of storage locations configured to store containers containing items and being accessible to the plurality of mobile robots. It further includes a recovery mobile robot including: a locomotion system configured to allow movement of the recovery mobile robot about the facility; a body; and at least one of: a towing attachment coupled to a portion of the body configured to facilitate the recovery mobile robot to attach to and tow an incapacitated mobile robot along a first pathway; and an extendable lift mechanism supported by the body and configured to facilitate the recovery mobile robot to exert a force against an incapacitated mobile robot in a second pathway.

[0041] In some implementations, the first pathway comprises a horizontal pathway, the incapacitated mobile robot being disposed on the horizontal pathway; and the towing attachment is configured to tow the incapacitated mobile robot along the horizontal pathway. In some implementations, the second pathway comprises a vertical pathway, the incapacitated mobile robot being disposed in the vertical pathway; and the extendable lift mechanism is configured to exert a force against the incapacitated mobile robot in the vertical pathway to align it with one or more rails in the vertical pathway along which the plurality of mobile robots move within the vertical pathway. In some implementations, the towing attachment is pivotally connected to the body, the towing attachment being pivotable between an upright non-operational position during travel by the recovery mobile robot and a recovery operational position upon arrival at the incapacitated mobile robot. In some implementations, the towing attachment comprises two support members configured to support wheels of the incapacitated mobile robot. In some implementations, the system further includes: a first arm supported by the body and configured to be extendable in anupward direction relative to the recovery mobile robot; and a second arm supported by the body and configured to be extendable in a downward direction relative to the recovery mobile robot. In some implementations, the recovery mobile robot is configured to use one of the first arm or the second arm to move the incapacitated mobile robot to a position in the first pathway where the towing attachment can attach to the incapacitated mobile robot. In some implementations, the recovery mobile robot further includes at least one sensor configured to facilitate at least one of: attachment of the towing attachment to the incapacitated mobile robot; and extension of the extendable lift mechanism to engage the incapacitated mobile robot.

[0042] In another form, there is provided a method of assisting incapacitated mobile robots, the method including: by a recovery mobile robot having a locomotion system, a body, and at least one of: a towing attachment coupled to a portion of the body and an extendable lift mechanism supported by the body: attaching the towing attachment to and towing an incapacitated mobile robot along a first pathway at a facility with a plurality of pathways configured for movement by a plurality of mobile robots therealong, the facility including a plurality of storage locations configured to store containers containing items and being accessible to the plurality of mobile robots; or contacting the incapacitated mobile robot with the extendable lift mechanism and exerting a force against the incapacitated mobile robot in a second pathway.

[0043] In some implementations, the method further includes receiving notification that the incapacitated mobile robot has become incapacitated at the facility. In some implementations, the method further includes determining that the incapacitated mobile robot has become incapacitated in the first pathway or the second pathway. In some implementations, the method further includes: moving and positioning the recovery mobile robot adjacent the incapacitated mobile robot in the first pathway; moving the towing attachment to an operative position; and supporting the incapacitated mobile robot with the towing attachment. In some implementations, the method further includes: moving and positioning the recovery mobile robot above or below the incapacitated mobile robot in the second pathway. In some implementations, the method further includes: extending the extendable lift mechanism to cause it to make contact with the incapacitated mobile robot in the second pathway. In some implementations, the method further includes: exerting a force against the incapacitated mobile robot to cause it to be aligned in the second pathway. In some implementations, in the method, the first pathway comprises a horizontalpathway, the incapacitated mobile robot being disposed on the horizontal pathway; and the towing attachment being configured to tow the incapacitated mobile robot along the horizontal pathway. In some implementations, in the method, the second pathway comprises a vertical pathway, the incapacitated mobile robot being disposed in the vertical pathway; and the extendable lift mechanism being configured to exert a force against the incapacitated mobile robot in the vertical pathway to align it with one or more rails in the vertical pathway along which the plurality of mobile robots move within the vertical pathway. In some implementations, the method further includes: pivoting the towing attachment between an upright non-operational position during travel by the recovery mobile robot and a recovery operational position upon arrival at the incapacitated mobile robot. In some implementations, the recovery mobile robot further includes: a first arm supported by the body and configured to be extendable in an upward direction relative to the recovery mobile robot; and a second arm supported by the body and configured to be extendable in a downward direction relative to the recovery mobile robot. In some implementations, the method further includes: using one of the first arm or the second arm to move the incapacitated mobile robot to a position in the first pathway where the towing attachment can attach to the incapacitated mobile robot.

[0044] In another form, there is provided a mobile robot assistance system. The system includes: a facility with a plurality of pathways configured for movement by a plurality of mobile robots therealong, the facility including a plurality of storage locations configured to store containers containing items and being accessible to the plurality of mobile robots. It also includes a recovery mobile robot including: a power supply; a locomotion system configured to facilitate movement of the recovery mobile robot; a body comprising a compartment configured to transport a battery separate from the power supply; and a first power connector disposed on the body. In the system, the recovery mobile robot is configured to transfer charge to an incapacitated mobile robot, the incapacitated mobile robot having a second power connector configured to receive charge through engagement with the first power connector of the recovery mobile robot.

[0045] In some implementations, the recovery mobile robot is configured to use either its own power supply or a transported battery to transfer charge to the incapacitated mobile robot. In some implementations, the power supply of the recovery mobile robot comprises a plurality of supercapacitors. In some implementations, the recovery mobile robot includes two first powerconnectors, one first power connector disposed in a front end of the body and the other first power connector disposed in a rear end of the body. In some implementations, the two first power connectors are configured to be engageable with either of two corresponding second power connectors, one second power connector disposed in a front end of the incapacitated mobile robot and the other second power connector disposed in a rear end of the incapacitated mobile robot. In some implementations, the recovery mobile robot further includes at least one sensor configured to facilitate alignment of the recovery mobile robot with the incapacitated mobile robot. In some implementations, the recovery mobile robot is configured to push the incapacitated mobile robot to a location based on a determination that the incapacitated mobile robot remains incapacitated following transfer of charge. In some implementations, each of the first power connector and the second power connector comprises a data connector for establishing a data connection and communicating data between the recovery mobile robot and the incapacitated mobile robot. In some implementations, the recovery mobile robot transmits instructions to the incapacitated mobile robot to release its brakes through the data connection.

[0046] In another form, there is provided a method of assisting incapacitated mobile robots, the method including: by a plurality of mobile robots, moving along a plurality of pathways at a facility, the facility including a plurality of storage locations configured to store containers containing items and being accessible to the plurality of mobile robots; by a recovery mobile robot comprising a power supply, a body with a compartment configured to transport a battery separate from the power supply, and having a first power connector disposed on the body, the recovery mobile robot: moving to a location adjacent to an incapacitated mobile robot, the incapacitated mobile robot having a second power connector configured to receive charge through engagement with the first power connector of the recovery mobile robot; and transferring charge to the incapacitated mobile robot.

[0047] In some implementations, the method further includes: by the recovery mobile robot, using either its own power supply or a transported battery to transfer charge to the incapacitated mobile robot. In some implementations, in the method, the power supply of the recovery mobile robot includes a plurality of supercapacitors. In some implementations, the recovery mobile robot comprises two first power connectors, one first power connector disposed in a front end of the body and the other first power connector disposed in a rear end of the body.In some implementations, the two first power connectors are configured to be engageable with either of two corresponding second power connectors, one second power connector disposed in a front end of the incapacitated mobile robot and the other second power connector disposed in a rear end of the incapacitated mobile robot. In some implementations, the method further includes: receiving notification that the incapacitated mobile robot has become incapacitated; and receiving notification of a location of the incapacitated mobile robot. In some implementations, the method further includes: determining that the recovery mobile robot will transport a battery to transfer charge to the incapacitated mobile robot; and receiving the battery in the compartment. In some implementations, the method further includes: aligning the recovery mobile robot with the incapacitated mobile robot. In some implementations, the method further includes: by the recovery mobile robot, pushing the incapacitated mobile robot to a location based on a determination that the incapacitated mobile robot remains incapacitated following transfer of charge. In some implementations, the method further includes: establishing a data connection between the first power connector and the second power connector and communicating data between the recovery mobile robot and the incapacitated mobile robot. In some implementations, the method further includes: instructing the incapacitated mobile robot to release its brakes through the data connection.

[0048] In one aspect, and without limitation, this disclosure is directed generally to a facility, such as an order fulfillment facility, that includes multiple mobile robots (or bots) that operate to pick and transfer containers in the context of an automated storage and retrieval system. In one form, bots move about the facility and retrieve containers, or totes, of goods that are stored in specific storage locations in the facility, as part of the automated storage and retrieval system. The facility may include decks and aisles (or horizontal pathways) and climbing channels / vertical towers (or vertical pathways) that may be accessed by the bots. In some situations, a specific bot may need to be assisted or recovered. These or other similar situations may require some form of assistance, such as charging or reorientation of an incapacitated bot, or its removal from the system.

[0049] Currently, any scenario requiring assistance or recovery of the bots may require an emergency stop (e-stop) of part or all of the system, i.e., complete stoppage of all or part of the system. In one aspect, and without limitation, it may be desirable to minimize the number of partial or complete system stops that are required in case of an error or anomaly involving a bot. Somescenarios of mishaps may require an individual, such as a technician, to physically enter a portion of the system to address the bot. In this instance, the system and / or facility may be shut down partially or completely to ensure the safety of the individual.

[0050] In one aspect, and without limitation, the present disclosure relates to assisting or recovering an incapacitated bot by using the already present bots in the system without e-stopping or requiring a technician to enter the system. In one aspect, a recovery bot may be equipped with a tow attachment, such as a mini auto-load wheel lift attachment, to move an incapacitated bot that is located in an aisle. For example, the mini auto-load wheel lift attachment may be modular and may be mounted on bots designated as recovery bots, which may not be used for tote transfer (like the standard bots). A gripper may attach to the wheels of an incapacitated bot to lift it and to move it to a desired location. In another aspect, the recovery bot may be equipped with an extendable lift mechanism (in addition to or as an alternative to the tow attachment), which may be used to nudge incapacitated robots in vertical pathways into alignment with rails in the vertical pathways.

[0051] In one aspect, and without limitation, the present disclosure also relates to a recovery bot that may assist or recover an incapacitated bot by providing charge to the incapacitated bot. In this circumstance, it is contemplated that the power source of the incapacitated bot may be depleted. The recovery bot may seek to donate some of its own charge to the incapacitated bot via data / power connections on the bots. Alternatively, or in addition, the recovery bot may transport a battery (separate from its power source) that it may utilize to try to charge the incapacitated bot. This concept may utilize a bot-to-bot interface in order to recharge a downed bot, either by transferring power directly from the recovery bot to the downed bot or via a separate energy storage device, such as a battery pack.

[0052] FIG. 1A shows a partial view of an embodiment of an order fulfillment facility 100 showing a storage structure 102, including a number of bays 104 of storage locations 106. In particular, each bay 104 includes a y-z array of storage locations 106 in horizontal rows and level changing towers, or vertical towers, along the rows. As explained below, mobile robots 150 may travel between storage levels in the z-direction within the level changing towers. Pairs of bays 104 may be arranged to face each other, separated by pathways 108. In one form, it is contemplated that the pathways may be aisles 108. An aisle 108 may have a width such that a mobile robot 150 traveling within an aisle 108 may transfer totes to the bays 104 on either side of the aisle 108. Asexplained hereinafter, the aisles 108 may be wide enough for a human to enter into an aisle 108 between bays 104 to make repairs or otherwise service components within an aisle 108.

[0053] The order fulfillment facility 100 may further include decks 112 (or transit planes or areas) spaced apart at different horizontal levels of the storage structure 102. The decks 112 may extend between the aisles 108 so that robots 150 can maneuver in the x-y plane of each deck 112 to travel between different aisles 108. In some embodiments, the decks 112 may be vertically spaced apart from each other, so that a technician can reach all areas within an aisle 108 serviced by a particular deck 112. The spacing between decks 112 may be different in various embodiments. In addition to providing access to the aisles 108, each pair of decks 112 allows transfers by mobile robots 150 to / from a workstation 110. In some forms, mobile robots 150 may come to a workstation 110 from a first deck 112-1, and mobile robots 150 may exit a workstation 110 from a second deck 112-2. Alternatively, in some forms, mobile robots 150 may come to a workstation 110 from deck 112-2 and exit from first deck 112-1.

[0054] FIG. IB shows examples of workstations 110. In some embodiments, each workstation 110 is equipped to receive a pair of mobile robots 150. A first mobile robot 150 at a workstation 110 may carry product containers (or totes) with items for fulfilling product requests. A second mobile robot 150 at the workstation 110 may carry order containers (or totes) within which items from the product totes are placed to fulfill product requests. Workers at a workstation 110 manually transfer items from a product tote to an order tote under guidance of an inventory control system at the workstation 110.

[0055] The mobile robots 150 for both the product and order totes arrive from one of the decks, for example deck 112-1. Once items are transferred from the product totes to the order totes, the mobile robots 150 may depart the workstation 110, for example via deck 112-2. Mobile robots 150 carrying product and order totes continuously cycle through the workstations 110. In FIG. 1A, each workstation 110 is serviced by a single deck 112, which serves as the entry to, and exit from, the workstation 110. Further details relating to the structure and operation of embodiments of the workstations are disclosed in U.S. Patent No. 10,040,632 and U.S. Patent No. 11,142,398, which patents are incorporated by reference herein in their entirety. In some forms, as described further below, it may be desirable to attach or position a mobile robot station on or adjacent to an aisle 108 or deck 112 that can receive a mobile robot 150 needing servicing.

[0056] As noted above, the order fulfillment facility 100 may further include a number of mobile robots 150 for transferring totes or other product containers to and from workstations 110 and storage locations 106 in the bays 104. In certain embodiments, mobile robots 150 may be self- guided so as to move horizontally within aisles 108 to transfer totes or other product containers between the mobile robots 150 and storage locations 106. For example, a track system including horizontal rails may be affixed to bays 104 within an aisle 108 at different vertical levels. The horizontal rails provide access to storage shelves on either side of an aisle 108 in the x-direction on a given level. As noted above, the bays 104 may include level changing towers within which the mobile robots 150 may travel vertically in the z-direction between levels of storage locations 106.

[0057] The decks 112 allow inter-aisle travel of mobile robots 150 at different levels of the storage structure 102. Further details of storage structures, track systems, and mobile robots 150 that may be used in conjunction with the present technology are described for example in the following U.S. patents: U.S. Patent No. 9,139,363; U.S. Patent No. 10,435,241; and previously mentioned U.S. PatentNo. 11,142,398, which patents are each incorporated by reference herein in their entirety.

[0058] Accordingly, in some forms, there is disclosed a facility 100 with pathways 108 and decks 112, and with mobile robots 150 configured to move along the pathways 108 and decks 112 at the facility 100. The facility 100 may be in the form of an order fulfillment facility that includes storage locations 106 for storing containers containing goods / items, with each storage location 106 being accessible to mobile robots 150 by a pathway 108. Further, mobile robots 150 are configured to access the storage locations 106 to deposit or retrieve containers at the storage locations 106.

[0059] The order fulfilment facility 100 described above is one example of a facility 100 where mobile robots 150 move about the facility 100 engaged in certain tasks. During the course of this movement, mobile robots 150 may encounter circumstances that cause them to become incapacitated. These circumstances may be internal (such as an internal component failure) or external (such as running into an obstacle). In these instances, it is desirable to be able to use another mobile robot, a recovery mobile robot, that can provide assistance. In some forms, therecovery mobile robot may tow the incapacitated mobile robot, may help it to become aligned with rails of a vertical pathway, or may transfer charge to it.

[0060] FIG. 2A shows a schematic example of a mobile robot assistance system 200. It is generally contemplated that this system 200 involves a recovery mobile robot that can assist or recover an incapacitated mobile robot at a facility. It is also contemplated that the recovery mobile robot may have a towing attachment to move an incapacitated mobile robot that is in a deck or aisle (horizontal pathway). In addition, or alternatively, the recovery mobile robot may also include an extendable lift mechanism to realign an incapacitated mobile robot that may be stuck or otherwise disposed in a vertical pathway.

[0061] The system 200 may include a facility 202 with a plurality of pathways configured for movement mobile robots 150. The facility 202 may include a plurality of storage locations 204 configured to store containers containing items and being accessible to the mobile robots 1 0. An example of a facility 100, such as an order fulfillment facility, was described above and is incorporated in this description.

[0062] The system 200 also includes a recovery mobile robot 206. In one form, the recovery mobile robot 206 includes a locomotion system 208 to allow movement of the recovery mobile robot about the facility 202. In one form, the locomotion system 208 may cooperate with a track system that may be in the form of rails or guidelines, such as magnetic guidelines, which may include navigational aids, such as RFID tags. The track system may include rails, guidelines, and / or some combination thereof. In one example, rails may be used in the aisles 108, while guidelines may be embedded in panels forming at least some of the decks 112. The locomotion system 208 enables the recovery mobile robot to move to the area of the incapacitated mobile robot 210.

[0063] The recovery mobile robot 206 further includes a body 212 and structure to enable the recovery mobile robot 206 to recover or assist the incapacitated mobile robot 210. It may include a towing attachment 214 coupled to a portion of the body 212 that allows the recovery mobile robot 206 to attach to and tow the incapacitated mobile robot 210. It is generally contemplated that this towing attachment 214 is usable for incapacitated mobile robots 210 that are incapacitated on a horizontal pathway 216 and that can be towed along the horizontal pathway216. This towing attachment 214 is preferably a modular towing mechanism that does not interfere with other structures and structural components of the facility.

[0064] In addition, or as an alternative, the recovery mobile robot 206 may be equipped with an extendable lift mechanism 218 supported by the body 212 that allows the recovery mobile robot 206 to exert a force against the incapacitated mobile robot 210. It is generally contemplated that this extendable lift mechanism 218 is usable for incapacitated mobile robots 210 that may be misaligned with respect to rail(s) in a vertical pathway 220. The exertion of this force seeks to realign them with the rail(s) along which the mobile robots 150 move within the vertical pathway 220. In one form, these rail(s) may be charge rail(s) that provide power to the mobile robots 150.

[0065] FIG. 2B shows the recovery mobile robot 206 on an aisle (horizontal pathway 216) and at a level changing tower (vertical pathway 220). Some of the detail has been removed so as just to show the recovery mobile robot 206, aisles 216 formed by two rails 215, and two supports of the level changing tower 220. The recovery mobile robot 206 may include pinions 217 that enable it to move up and down along the vertical pathway 220. The pinion 217 may be extended to engage and be received in the rack 219.

[0066] Next, an example of a charging portion of a support is shown. As shown in FIG. 2C, a charge rail 221 may be incorporated into the vertical track on one or both sides of a level changing tower 223. Charge rail 221 may be electrically coupled to a facility power source 225 so as to receive the voltage from the facility power source 225. In some forms, the voltage received in each of the one or more charge rails 221 may be an AC voltage, at for example 120 V, 220 V, or 240 V. It is understood that facility power source may provide other AC voltages in other forms. Additionally, a voltage converter may be provided between the facility power source 225 and charge rail 221 to convert the voltage to DC voltage, or a voltage which is different than the facility power source 225. Further details regarding charge rails and systems, such as may be used with mobile robots, are described in U.S. Published Patent Application No. 2019 / 0245366, which is incorporated herein by reference in its entirety.

[0067] Further, the recovery mobile robot 206 may include an additional feature (one or more arms) to address incapacitated mobile robots 210 that may be incapacitated at the end of an aisle, or in edge or corner locations. In this location, it may be difficult for a recovery mobile robot 206 to position itself in front of an incapacitated mobile robot 210 to allow it to attach to and towthe incapacitated mobile robot 210. The recovery mobile robot 206 may use these arms to push, drag, or grab the incapacitated mobile robot 210 to maneuver it to a better position for access by the recovery mobile robot 206.

[0068] In one form, the recovery mobile robot 206 includes a first arm 222 supported by the body 212 that is extendable in an upward direction relative to the recovery mobile robot 206 and further includes a second arm 224 supported by the body 212 that is extendable in a downward direction relative to the recovery mobile robot 206. The two arms 222, 224 may be in the form of two linear stages (that extend linearly), one of which is movable upwardly and the other of which is movable downwardly. In one form, the arms 222, 224 may be extended to engage the frame or other portion of the incapacitated mobile robot 210, and movement of the mobile recovery robot 206 may then cause corresponding movement of the incapacitated mobile robot 210.

[0069] It is contemplated that the recovery mobile robot 206 may position itself beneath the incapacitated mobile robot 210, such as in an aisle located immediately below the aisle of the incapacitated mobile robot 210. From this position, it may then extend the first arm 222 to engage the incapacitated mobile robot 210. Alternatively, it is contemplated that the recovery mobile robot 206 may position itself above the incapacitated mobile robot 210, such as in an aisle located immediately above the aisle of the incapacitated mobile robot 210. From this position, it may then extend the second arm 224 to engage the incapacitated mobile robot 210.

[0070] In other words, the recovery mobile robot 206 may use one of the first arm 222 or the second arm 224 to move the incapacitated mobile robot 210 to a position in the horizontal pathway 216 where the towing attachment 214 can attach to the incapacitated mobile robot 210. The first and second arms 222, 224 may push the incapacitated mobile robot 210 to a more accessible position. It is also contemplated that the ends of the first and second arms 222, 224 optionally may be equipped with some sort of gripping or grabbing mechanism, such as a hook, a claw, a gripping portion, adhesive, etc., to facilitate engaging and moving the incapacitated mobile robot 210.

[0071] The recovery mobile robot 206 may further include sensor(s) 226. The sensor(s) 226 may be utilized to facilitate attachment of the towing attachment 214 to the incapacitated mobile robot 210 and / or to facilitate extension of the extendable lift mechanism 218 to engage the incapacitated mobile robot 210. For example, the sensor(s) 226 may include an imaging sensor,such as some form of camera, to allow the recovery mobile robot 206 to position itself and to attach the towing attachment 214 for an incapacitated mobile robot 210 in a horizontal pathway 216. Further, an imaging sensor 226 may be used to allow the recovery mobile robot 206 to position itself and to extend the extendable lift mechanism 218 to contact the incapacitated mobile robot 210 in a vertical pathway 220.

[0072] The recovery mobile robot 206 may also include a controller 228 that is configured to allow the recovery mobile robot 206 to perform certain operations and functions. For example, it may control movement of the locomotion system 208, the towing attachment 214, the extendable lift mechanism 218, and the first and second arms 222, 224. In one form, it is contemplated that the controller 228 may be in communication with a centralized control circuit that is remote from the recovery mobile robot 206 and that may provide it with instructions. Further, it is contemplated that the controller 228 may be in communication with other mobile robots 150.

[0073] In this context, the terms control circuit and controller 228 refer broadly to any microcontroller, computer, or processor-based device with processor, memory, and programmable input / output peripherals, which is generally designed to govern the operation of other components and devices. It is further understood to include common accompanying accessory devices, including memory, transceivers for communication with other components and devices, etc. These architectural options are well known and understood in the art and require no further description here. The control circuit or controller 228 may be configured (for example, by using corresponding programming stored in a memory as will be well understood by those skilled in the art) to carry out one or more of the steps, actions, and / or functions described herein.

[0074] As stated, the control circuit or controller 228 may include, or be coupled to, common accompanying accessories, such as, for example, a memory, a network interface, and wireless network(s). The memory can, for example, store non-transitorily computer instructions that cause the control circuit or controller 228 to operate as described herein, when the instructions are executed, as is well known in the art. Further, the network interface may enable the control circuit or controller 228 to communicate with other elements (both internal and external to the system). This network interface is well understood in the art. The network interface can communicatively couple the control circuit or controller 228 to the wireless network and whatever other networks may be appropriate for the circumstances.

[0075] FIGS. 3-8 show an example of a recovery mobile robot 300 with a towing attachment 302. This example incorporates the description of the general structure and operation of the towing attachment above. As described, it is generally contemplated that the recovery mobile robot 300 may use the towing attachment 302 to assist and recover incapacitated mobile robots in horizontal pathways of a facility.

[0076] FIG. 3 shows the recovery mobile robot 300 with the towing attachment 302 in a raised, non-operational position. It is generally contemplated that the towing attachment 302 may be maintained in this position while traveling to the location of an incapacitated mobile robot 304 (or otherwise not using the towing attachment 302). FIGS. 4 and 5 show the recovery mobile robot 300 with the towing attachment in a lowered, operational position. It is generally contemplated that the towing attachment 302 may be lowered to this position after the recovery mobile robot 300 has oriented itself in front of the incapacitated mobile robot 304.

[0077] As can be seen, in one form, the towing attachment 302 is pivotally connected to the body 306. In this form, the towing attachment 302 is pivotable between an upright non- operational position during travel by the recovery mobile robot 300 and a recovery operational position upon arrival at the incapacitated mobile robot 304. Further, the towing attachment 302 may include two support members 308, 310 (which may preferably include gripping features) configured to support wheels 312 of the incapacitated mobile robot 304.

[0078] FIGS. 6-8 show the recovery mobile robot 300 engaging the incapacitated mobile robot 304. FIG. 6 shows the recovery mobile robot 300 in front of the incapacitated mobile robot 304 with the towing attachment 302 raised. FIG. 7 shows the recovery mobile robot 300 after the towing attachment 302 has been pivotably lowered. In some forms, the horizontal pathways may be in the form of two spaced rails such that the towing attachment 302 may be lowered between the two spaced rails and below the level of the wheels 312 of the incapacitated mobile robot 304. The towing attachment 302 may then be lifted to engage the wheels 312. FIG. 8 shows the recovery mobile robot 300 following rearward movement where the towing attachment 302 engages and supports wheels 312 of the incapacitated mobile robot 304.

[0079] FIGS. 9-12 show another example of a recovery mobile robot 400 with a towing attachment 402. In this example, the towing attachment 402 is connected to the body 404 and uses a rotary drive 406 to pivotably move two support members 408, 409. FIG. 9 shows the towingattachment in an upright position, and FIG. 10 shows the towing attachment 402 in a lowered, recovery position. FIG. 11 shows an exploded view of the rotary drive 406 and the two support members 408, 409, and FIG. 12 shows the towing attachment 402 engaging and supporting a portion of the incapacitated mobile robot 410 in front of its wheels 412.

[0080] FIGS. 13 and 14 show another example of a recovery mobile robot 500 with a towing attachment 502. In this example, the towing attachment 502 is connected to the body 504 and may use a linear drive 506. FIG. 13 shows the towing attachment 502 in a lowered, recovery position with support members 508, 509. FIG. 14 shows the towing attachment 502 engaging and supporting the wheels 510 of the incapacitated mobile robot 512.

[0081] As should be understood from the above examples, various types and structures of towing attachments may be used. For instance, the towing attachment may use various mechanisms for maintaining it in an upright, non-operational position and for moving it to a lowered, operational position. Further, it should be understood the towing attachment may use any of various shaped support members (or lifting interfaces) and any of various lifting mechanisms that may be used to engage and support an incapacitated mobile robot at designated lifting points on the body. For example, potential lifting points on the incapacitated mobile robot may include any robust lifting points, such as the wheels, wheel hubs, trucks, motor, frame, etc.

[0082] Next, as stated above, the recovery mobile robot may include arms to maneuver an incapacitated mobile robot when the incapacitated mobile robot is in a position that is inaccessible fortowing. FIGS. 15-18 show an example of a recovery mobile robot 600 with maneuvering arms 602, 604. This example incorporates the description of the general structure and operation of the maneuvering arms above. As described, it is generally contemplated that the recovery mobile robot 600 may use the maneuvering arms 602, 604 for the recovery of incapacitated mobile robots in horizontal pathways of a facility.

[0083] FIGS. 15 and 16 show the maneuvering arms 602, 604. The first arm 602 is coupled to a first motor or drive 606 that vertically moves the first arm 602 between an elevated position and a lowered position. Similarly, the second arm 604 is coupled to a second motor or drive 608 that vertically moves the second arm 604 between an elevated position and a lowered position. FIGS. 15 and 16 show both the first and second arms 602, 604 in elevated positions.

[0084] FIG. 17 shows the recovery mobile robot 600 engaging the incapacitated mobile robot 610 with the first arm 602. As can be seen, the recovery mobile robot 600 is generally positioned below the incapacitated mobile robot 610, such as in an aisle immediately below the aisle of the incapacitated mobile robot 610. In this position, it can extend the first arm 602 to an elevated position to engage and move the incapacitated mobile robot 610.

[0085] FIG. 18 shows the recovery mobile robot 600 engaging the incapacitated mobile robot 610 with the second arm 604. As can be seen, the recovery mobile robot 600 is generally positioned above the incapacitated mobile robot 610, such as in an aisle immediately above the aisle of the incapacitated mobile robot 610. In this position, it can extend the second arm 604 to a lowered position to engage and move the incapacitated mobile robot 610.

[0086] Next, as stated above, the recovery mobile robot may include an extendable lift mechanism to assist an incapacitated mobile robot located in a vertical pathway. FIGS. 19 and 20 show an example of a recovery mobile robot 700 with an extendable lift mechanism 702. This example incorporates the description of the general structure and operation of the extendable lift mechanism above. As described, it is generally contemplated that the recovery mobile robot 700 may use the extendable lift mechanism 702 for the recovery of incapacitated mobile robots in vertical pathways (vertical towers or climbing channels) of a facility.

[0087] FIG. 19 shows a recovery mobile robot 700 having positioned itself beneath an incapacitated mobile robot 704. In one form, it is contemplated that the incapacitated mobile robot 704 may have become misaligned in a vertical pathway of the facility. In one form, it is contemplated that the incapacitated mobile robot 704 may be stuck between levels of the facility and may need to be moved to one of the levels. In another form, it is contemplated that the recovery mobile robot 700 moves along rail(s) of the vertical pathway, which may include a charging rail that transfers charge to the recovery mobile robot 700. As another non-limiting example, the incapacitated mobile robot 704 may have lost contact with the charging rail and may have eventually lost power due to this loss of contact. In FIG. 21, the extendable lift mechanism 702 is in a lowered, non-engagement position.

[0088] FIG. 20 shows the extendable lift mechanism 702 in an elevated, engagement position. As can be seen, the extendable lift mechanism 702 can be used to exert a force against the underside of the incapacitated mobile robot 704. In one form, the recovery mobile robot 700may be able to push or nudge the incapacitated mobile robot 704 to another level where it may be removed. Alternatively, in another form, it is contemplated that the extendable lift mechanism 702 may be able to push or nudge the incapacitated mobile robot 704 such that it is realigned and regains contact with a charging rail and can recharge.

[0089] As should be understood, various types and structures of extendable lift mechanisms 702 may be used. As one example, the extendable lift mechanism 702 may be a spiral lift mechanism that may operate in a spiraling manner to extend or retract the structure. Further, the extendable lift mechanism 702 may be located at various points of the body 706 of the recovery mobile robot 700. Further, as shown in FIGS. 21 and 22, a recovery mobile robot 700 may include both an extendable lift mechanism 702 and a towing attachment 708. In other forms, however, the recovery mobile robot 700 may just be equipped with one or the other.

[0090] FIG. 21 shows a process 800 for assisting or recovering incapacitated mobile robots (or downed bots). It is generally contemplated that the downed bot may be located at a horizontal pathway or vertical pathway in the facility. Further, it is generally contemplated that the recovery mobile robot (or tow bot) may include some or all of the components described above, such as, for example, components of recovery mobile robots 206, 300, 400, 500, 600, and 700.

[0091] At block 802, a bot is down (incapacitated) in the facility. It may become incapacitated for any of a variety of reasons, such as, for example, an internal failure, impacting an obstacle, or becoming misaligned with rails in a vertical pathway. A determination is made that the downed bot has become incapacitated in a pathway, i.e., a horizontal pathway or a vertical pathway. In one form, it is contemplated that the facility includes a communication network through which notification of the downed bot is received, along with the location of the downed bot. In some forms, sensors at the facility, such as cameras, may detect the downed bot.

[0092] At block 804, a determination is made as to whether a horizontal or vertical recovery might be performed. In some circumstances, neither recovery can be performed. In this instance, at block 805, the downed bot may have to be retrieved manually, such as by a technician.

[0093] At block 806, if a horizontal or vertical recovery can be made, a tow bot travels to the downed bot’s location. In some forms, it is generally contemplated that the tow bot has received instructions about the downed bot through the communication network, including thelocation of the downed hot. Further, at block 808, the tow hot is preferably a charged tow bot that is located, or parked, in a low traffic area near the downed bot.

[0094] At block 810, a determination is made as to whether a horizontal recovery might be performed. At block 812, if a horizonal recovery is possible, a determination is next made as to whether the downed bot is at the end of an aisle (horizontal pathway). At block 814, if the downed block is at the end of an aisle, the tow bot will initially use its arms to maneuver the downed bot to a position where it is accessible to the tow bot. For example, the tow bot may position itself above or below the downed bot and use arms (such as, without limitation, arms 602 or 604 described above and shown in FIGS. 15-18) to push, pull, grab, or drag the downed bot to an accessible position.

[0095] At block 816, once the downed bot is in an accessible position, the tow bot positions itself in front of the downed bot. At block 818, the tow bot lowers and positions its towing attachment (or auto lift load attachment). It is generally contemplated that the tow bot may use imaging sensor(s) (such as camera(s)) and / or other sensors to determine a location for the tow bot to position itself relative to the downed bot so as to use the towing attachment.

[0096] At block 820, the tow bot secures and lifts the downed bot. For example, the tow bot may use, without limitation, towing attachments 302, 402, or 502 in the manner described above and as shown in FIGS. 3-14 to support, secure, and lift the downed bot. In one form, the tow bot may ensure that the downed bot is safely supported and secured by performing a few trials. At block 822, the tow bot moves the downed bot to a designated location. In other words, after successfully securing the downed bot, the tow bot moves the downed bot to a designated location where it may be serviced.

[0097] At block 824, following transport of the downed bot to the designated location, the tow bot may move to a low traffic area to wait for the next disabled bot requiring assistance. At block 826, a technician interacts with the downed bot at the designated location. In other words, the technician may repair or provide maintenance to the downed bot so that it may be returned for operation in the facility. At block 828, the process 800 is complete.

[0098] In some forms, the tow bot may be equipped with cameras and / or other sensors to capture images or information regarding the downed bot or nearby structure at the facility. For example, they may be used to determine if there is damage to the downed bot, see if an RFID tagis missing, check if there is some sort of protrusion in a tote, check the downed hot or nearby structure to see if there is a misalignment, check communication issues, etc. These images and information may be useful for the technician in maintaining or repairing the downed bot or a portion of the facility.

[0099] Returning to block 810, if a determination is made that a horizontal recovery is not to be performed, the process 800 proceeds to block 830. At block 830, a determination is made as to whether a vertical recovery might be performed. If not, at block 804, a determination has been made that neither a horizontal nor a vertical recovery can be performed, so the downed bot is retrieved manually.

[0100] At block 830, if a determination is made that a vertical recovery might be performed, the process 800 proceeds to block 832. At block 832, the tow bot positions itself below the downed bot in a vertical pathway (although in some circumstances it may be positioned above). It is generally contemplated that sensors may be used to allow the tow bot to position itself relative to the downed bot. At block 834, the tow bot activates and extends a lift mechanism and contacts or engages the downed bot. For example, the tow bot may use lift mechanisms, such as, without limitation, lift mechanism 702 described above and shown in FIGS. 19 and 20. Further, at block 836, tow bot sensors, such as cameras and / or other sensors, may be used to help guide the lift mechanism to engage the downed bot.

[0101] In one form, it is contemplated that the downed bot may be misaligned with rail(s) in the vertical pathway. At block 838, the tow bot uses the lift mechanism to nudge, push, or otherwise exert a force against the downed bot to align it with rail(s) of the vertical pathway. In one form, it is contemplated that once the downed bot is aligned with the rail(s) (which may include a charging rail), the downed bot can move freely and resume normal function. At block 840, following use of the lift mechanism, the tow bot retracts the lift mechanism.

[0102] At block 824, following engagement with the downed bot in the vertical pathway, the tow bot may move to a low traffic area to wait for the next disabled bot requiring assistance. At block 826, a technician interacts with the downed bot at the designated location. In other words, the technician may repair or provide maintenance to the downed bot so that it may be returned for operation in the facility. At block 828, the process 800 is complete.

[0103] FIG. 22 shows a schematic example of another example of a mobile robot assistance system 900. It is generally contemplated that this system 900 involves a recovery mobile robot 906 that can assist or recover an incapacitated mobile robot at a facility. In this form, it is contemplated that the recovery mobile robot 906 may use its own power supply, or may use a transported battery, to transfer charge to an incapacitated mobile robot. In some forms, it is contemplated that this recovery mobile robot may additionally incorporate some of the components of the recovery mobile robots 206, 300, 400, 500, 600, and 700 described above, such as towing attachments 214, 302, 402, and 708; arms 222, 224, 602, and 604; and / or extendable lift mechanisms 218 and 702; to provide a number of options for assisting or recovering an incapacitated mobile robot. Similarly, some of the components described below may be incorporated into recovery mobile robots 206, 300, 400, 500, 600, and 700.

[0104] The system 900 may include a facility 902 with a plurality of pathways 903 configured for movement mobile robots 150. The facility 902 may include a plurality of storage locations 904 configured to store containers containing items and being accessible to the mobile robots 150. An example of a facility 100, such as an order fulfillment facility, was described above and is incorporated in this description.

[0105] The system 900 also includes a recovery mobile robot 906. In one form, the recovery mobile robot 906 includes a locomotion system 908 to allow movement of the recovery mobile robot about the facility 902. In one form, the locomotion system 908 may cooperate with a track system that may be in the form of rails or guidelines, such as magnetic guidelines, which may include navigational aids, such as RFID tags. The track system may include rails, guidelines, and / or some combination thereof. In one example, rails may be used in the aisles 108, while guidelines may be embedded in panels forming at least some of the decks 112. The locomotion system 208 enables the recovery mobile robot to move to the area of the incapacitated mobile robot 910.

[0106] The recovery mobile robot 206 further includes a power supply 912 (or charge assembly). In one form, the power supply 912 of the recovery mobile robot 906 may include an onboard rechargeable energy storage device, which may include a bank of supercapacitors. In this form, any of a variety of supercapacitors may be used in the power supply 912, including, for example, regular electric double layer capacitors, lithium supercapacitors, and ultra-lowimpedance capacitors. It is further understood that the power supply 912 may be or include a variety of rechargeable power supplies other than supercapacitors in other embodiments, including, for example, ordinary capacitors, electrochemical batteries, and other types of rechargeable power sources. Additional details regarding charge assemblies and charging systems, such as may be used with mobile robots, are described in U.S. Published Patent Application No. 2019 / 0245366, which was previously mentioned and is incorporated herein by reference in its entirety.

[0107] In addition, the recovery mobile robot 906 includes a body 914 and structure to enable the recovery mobile robot 906 to recover or assist the incapacitated mobile robot 910. The body 914 may include a compartment 916 that may be used to transport a battery separate from the power supply 912. In some circumstances, it is contemplated that the power supply 912 of the recovery mobile robot 906 may not be suited to, or may not have sufficient charge to, transfer charge to the incapacitated mobile robot 910. For example, where the power supply 912 is in the form of a bank of supercapacitors, this power supply 912 tends to be used or discharged relatively quickly, which may make relying on it to charge the incapacitated mobile robot 910 undesirable. Under these circumstances, it might be preferable to have a separate power source in the form of a battery that is transported in a compartment 916 of the recovery mobile robot 906.

[0108] The recovery mobile robot 906 also includes at least one power connector disposed in the body 914. For example, a power connector may be disposed at the front and / or rear ends of the body 914. In some forms, it is contemplated that recovery mobile robot 906 may include two power connectors, one at each end of the body 914. As can be seen in FIG. 22, in one form, the recovery mobile robot may include a front end power connector 918 and a rear end power connector 920. Having a power connector at both ends of the body 914 may provide flexibility in transferring charge when the incapacitated mobile robot 910 is at different positions and orientations on pathways 903 in the facility 902.

[0109] In other words, in one form, the recovery mobile robot 906 includes two power connectors 918, 920 with one first connector 918 disposed in a front end of the body 914 and with the other power connector 920 disposed in a rear end of the body 914. These two power connectors 918, 920 are engageable with either of two corresponding power connectors 922, 924 in the incapacitated mobile robot 910. Regarding the incapacitated mobile robot 910, it is generallycontemplated that one power connector 922 is also disposed in a front end and the other power connector 924 is disposed in a rear end. Further, in one form, it is generally contemplated that most or all of the mobile robots 150 at the facility 902 will have both power connectors in the event they become incapacitated at some time and require assistance. This approach may allow most or all mobile robots 150 to provide power or receive power and may facilitate their conversion (or retrofitting) and use as recovery mobile robots 906.

[0110] In operation, the recovery mobile robot 906 will preferably align itself with the incapacitated mobile robot 910 such that their respective power connectors engage to allow the transfer of charge. It is generally contemplated that the recovery mobile robot 906 includes sensor(s) 926, such as camera(s), to facilitate alignment of the recovery mobile robot 906 with the incapacitated mobile robot 910. Once aligned and in engagement, the recovery mobile robot 906 uses either its own power supply 912 or a transported battery to transfer charge to the incapacitated mobile robot 910. In other words, the incapacitated mobile robot 910 receives charge through a power connector that is engagement with a power connector of the recovery mobile robot 906.

[0111] In some forms, it is contemplated that the power connector(s) 918, 920 of the recovery mobile robot 906 and the power connector(s) 922, 924 also act as data connectors for establishing a data connection and communicating data between the recovery mobile robot 906 and the incapacitated mobile robot 910. In some forms, power may not be applied or transferred until a data connection is made. In some forms, for example, a spring loaded, magnetic connection may be made between the recovery mobile robot 906 and the incapacitated mobile robot 910.

[0112] Once a data connection is established, the recovery mobile robot 906 may transmit instructions to the incapacitated mobile robot 910 to release its brakes, as necessary, via the data connection. For example, it may be desirable for the recovery mobile robot 906 to push the incapacitated mobile robot 910 if the attempted transfer of charge does not resolve the incapacitation. Instructions to release the brakes may be needed to allow movement of the incapacitated mobile robot 910. The power / data connectors may be used to transmit a signal to the incapacitated mobile robot 910 to release its brakes. The recovery mobile robot 906 is configured to push the incapacitated mobile robot 910 to a location based on a determination that the incapacitated mobile robot 910 remains incapacitated following transfer of charge. Depending on the circumstances, the recovery mobile robot 906 may either position itself to use its front endto push the incapacitated mobile robot 910 forward or to use its rear end to push the incapacitated mobile robot 910 backward.[001131 The recovery mobile robot 906 may also include a controller 928 that is configured to allow the recovery mobile robot 906 to perform certain operations and functions, such as the ones described above. For example, it may control movement of the locomotion system 908 and transfer of charge via the power connector / s) 918, 920. In one form, it is contemplated that the controller 928 may be in communication with a centralized control circuit that is remote from the recovery mobile robot 906 and that may provide it with instructions. Further, it is contemplated that the controller 928 may be in communication with other mobile robots 150. In this context, the term controller 928 is generally the same as the controller 228 described above. It refers broadly to any microcontroller, computer, or processor-based device with processor, memory, and programmable input / output peripherals, which is generally designed to govern the operation of other components and devices. The description of controller 228 is generally incorporated herein.

[0114] FIGS. 23-26 show an example of a recovery mobile robot 1000. As can be seen, it includes a locomotion system 1002 and a body 1004 with a compartment 1006 that is configured to transport a battery 1008 that is separate from the power supply of the recovery mobile robot 1000. Further, a front end power connector 1010 and a rear end power connector 1012 are disposed in the body 1004. In FIG. 25, the recovery mobile robot 1000 is aligned with and in engagement with an incapacitated mobile robot 1014. In this position the recovery mobile robot 1000 can transfer charge to the incapacitated mobile robot 1014 or push it, if necessary.

[0115] FIG. 27 shows another example of a use for recovery mobile robot 1000 that takes advantage of the general incorporation of front and rear end power connectors in mobile robots 1016. In this example, the front end and rear end power connectors allow multiple mobile robots 1000, 1016 in a horizontal pathway, or aisle 1017, to be linked together to form a chain. In this form, a recovery mobile robot 1000 may transfer charge to one mobile robot 1016, which may then be transferred one-by-one to other mobile robots 1016 in the chain. In this example, the recovery mobile robot 1000 has a connection to a structure charge rail 1018, which allows all connected mobile robots 1016 in the chain to also receive a charge from the rail 1018.

[0116] FIG. 28 shows another process 1100 for assisting or recovering incapacitated mobile robots (or downed bots). It is generally contemplated that the downed bot is locatedfacility, such as an order fulfillment facility. Further, it is generally contemplated that the recovery mobile robot may include some or all of the components described above, such as, for example, components of recovery mobile robots 906 and 1000.

[0117] At block 1102, a bot is down (incapacitated) in the facility. It may become incapacitated for any of a variety of reasons, such as, for example, a loss of charge or some other internal or external event. A determination is made that the downed bot has become incapacitated. In one form, it is contemplated that the facility includes a communication network through which notification of the downed bot is received, along with the location of the downed bot. In some forms, sensors at the facility, such as cameras, may detect the downed bot.

[0118] At block 1104, a determination is made as to whether the downed bot can be recovered by another bot, i.e., by a recovery bot. In some circumstances, a recovery cannot be performed. For example, the downed bot may be in a location of the facility, or may be in a position, that does not allow for recovery by the recovery bot. In this instance, at block 1106, the downed bot may have to be retrieved manually.

[0119] If a recovery bot may be used, a recovery bot near the location of the downed bot is preferably used and receives instructions about the downed bot, such as via the communication network. Further, a determination may be made as to whether the recovery bot has enough charge to transfer to the downed bot. For example, if the recovery bot is low on charge, it may travel to a nearby charge rail to get sufficiently charged.

[0120] At block 1106, a determination is made as to whether a battery tote is required. There may be factors indicating that a battery tote is not required. For example, the recovery bot may be fully charged, and this charge may be sufficient to allow travel to and from the downed bot and to allow transfer of some charge to the downed bot. If a battery tote is not required, the process 1100 moves to block 1108. However, if a battery tote is required, at block 1110, the recovery bot first retrieves a battery pack tote, and the process 1100 then moves to block 1108.

[0121] At block 1108, the recovery bot travels to and reaches to the instructed location of the downed bot. It is generally contemplated that the recovery bot aligns with and engages the downed bot via power connectors on the recovery and downed bots, such as via power connectors 918, 920, 922, and / or 924 described above. At block 1112, the recovery bot transfers enough power to establish a data connection.

[0122] At block 1114, a determination is made as to whether the downed bot can be revived by charging alone. For example, the data connection may provide confirmation to the recovery bot, and / or to a centralized control circuit in communication with the recovery bot, that the downed bot is depleted or otherwise out of any charge. Alternatively, it may allow the recovery bot, or the centralized control circuit, to determine that the reason for incapacitation is not due to a loss of charge.

[0123] At block 1116, it has been determined that the downed bot might be revived by charging, and the recovery bot charges the downed bot until it becomes operable. At block 1118, once charged, the recovery bot may disconnect or disengage from the downed bot. At block 1120, following charging, the recovery bot and the downed bot are now able to resume their regular operations.

[0124] At block 1122, it has been determined that the downed bot might not be revived by charging, i.e., there may be some other problem with the downed bot, so the recovery bot will push the downed bot to a desired location. Initially, the recovery bot, and / or a centralized control circuit, determines a direction to push the downed bot. At block 1124, the recovery bot aligns itself with the front or the rear of the downed bot. It is generally contemplated that the recovery bot may use camera(s) and / or other sensors to accomplish this alignment and orientation.

[0125] At block 1126, the downed bot is instructed or commanded to release its brakes. In one form, the centralized control circuit transmits this instruction or command through the recovery bot. At block 1128, following release of the brakes, the recovery bot pushes the downed bot to a designated location. For example, this designated location may be a low traffic area or may be a location where a technician can readily access the downed bot for repair and maintenance. At block 1120, the recovery bot may resume its regular operation, and following repair of the downed bot, the downed bot may also resume its regular operation.

[0126] Those skilled in the art will recognize that a wide variety of other modifications, alterations, and combinations can also be made with respect to the above-described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.

Claims

CLAIMSWhat is claimed is:

1. A mobile robot assistance system comprising: a facility with a plurality of pathways configured for movement by a plurality of mobile robots therealong, the facility including a plurality of storage locations configured to store containers containing items and being accessible to the plurality of mobile robots; a recovery mobile robot comprising: a locomotion system configured to allow movement of the recovery mobile robot about the facility; a body; and at least one of: a towing attachment coupled to a portion of the body configured to facilitate the recovery mobile robot to attach to and tow an incapacitated mobile robot along a first pathway; and an extendable lift mechanism supported by the body and configured to facilitate the recovery mobile robot to exert a force against an incapacitated mobile robot in a second pathway.

2. The mobile robot assistance system of claim 1, wherein: the first pathway comprises a horizontal pathway, the incapacitated mobile robot being disposed on the horizontal pathway; and the towing attachment is configured to tow the incapacitated mobile robot along the horizontal pathway.

3. The mobile robot assistance system of claim 1, wherein: the second pathway comprises a vertical pathway, the incapacitated mobile robot being disposed in the vertical pathway; andthe extendable lift mechanism is configured to exert a force against the incapacitated mobile robot in the vertical pathway to align it with one or more rails in the vertical pathway along which the plurality of mobile robots move within the vertical pathway.

4. The mobile robot assistance system of claim 1, wherein the towing attachment is pivotally connected to the body, the towing attachment being pivotable between an upright non- operational position during travel by the recovery mobile robot and a recovery operational position upon arrival at the incapacitated mobile robot.

5. The mobile robot assistance system of claim 1, wherein the towing attachment comprises two support members configured to support wheels of the incapacitated mobile robot.

6. The mobile robot assistance system of claim 2, further comprising: a first arm supported by the body and configured to be extendable in an upward direction relative to the recovery mobile robot; and a second arm supported by the body and configured to be extendable in a downward direction relative to the recovery mobile robot.

7. The mobile robot assistance system of claim 6, wherein: the recovery mobile robot is configured to use one of the first arm or the second arm to move the incapacitated mobile robot to a position in the first pathway where the towing attachment can attach to the incapacitated mobile robot.

8. The mobile robot assistance system of claim 1, wherein the recovery mobile robot further comprises at least one sensor configured to facilitate at least one of: attachment of the towing attachment to the incapacitated mobile robot; and extension of the extendable lift mechanism to engage the incapacitated mobile robot.

9. A method of assisting incapacitated mobile robots, the method comprising:by a recovery mobile robot having a locomotion system, a body, and at least one of: a towing attachment coupled to a portion of the body and an extendable lift mechanism supported by the body: attaching the towing attachment to and towing an incapacitated mobile robot along a first pathway at a facility with a plurality of pathways configured for movement by a plurality of mobile robots therealong, the facility including a plurality of storage locations configured to store containers containing items and being accessible to the plurality of mobile robots; or contacting the incapacitated mobile robot with the extendable lift mechanism and exerting a force against the incapacitated mobile robot in a second pathway.

10. The method of claim 9, further comprising receiving notification that the incapacitated mobile robot has become incapacitated at the facility.

11. The method of claim 9, further comprising determining that the incapacitated mobile robot has become incapacitated in the first pathway or the second pathway.

12. The method of claim 9, further comprising: moving and positioning the recovery mobile robot adjacent the incapacitated mobile robot in the first pathway; moving the towing attachment to an operative position; and supporting the incapacitated mobile robot with the towing attachment.

13. The method of claim 9, further comprising: moving and positioning the recovery mobile robot above or below the incapacitated mobile robot in the second pathway.

14. The method of claim 13, further comprising: extending the extendable lift mechanism to cause it to make contact with the incapacitated mobile robot in the second pathway.

15. The method of claim 14, further comprising: exerting a force against the incapacitated mobile robot to cause it to be aligned in the second pathway.

16. The method of claim 9, wherein: the first pathway comprises a horizontal pathway, the incapacitated mobile robot being disposed on the horizontal pathway; and the towing attachment being configured to tow the incapacitated mobile robot along the horizontal pathway.

17. The method of claim 9, wherein: the second pathway comprises a vertical pathway, the incapacitated mobile robot being disposed in the vertical pathway; and the extendable lift mechanism being configured to exert a force against the incapacitated mobile robot in the vertical pathway to align it with one or more rails in the vertical pathway along which the plurality of mobile robots move within the vertical pathway.

18. The method of claim 9, further comprising: pivoting the towing attachment between an upright non-operational position during travel by the recovery mobile robot and a recovery operational position upon arrival at the incapacitated mobile robot.

19. The method of claim 9, wherein the recovery mobile robot further comprises: a first arm supported by the body and configured to be extendable in an upward direction relative to the recovery mobile robot; and a second arm supported by the body and configured to be extendable in a downward direction relative to the recovery mobile robot.

20. The method of claim 19, further comprising:using one of the first arm or the second arm to move the incapacitated mobile robot to a position in the first pathway where the towing attachment can attach to the incapacitated mobile robot.

21. A mobile robot assistance system comprising: a facility with a plurality of pathways configured for movement by a plurality of mobile robots therealong, the facility including a plurality of storage locations configured to store containers containing items and being accessible to the plurality of mobile robots; a recovery mobile robot comprising: a power supply; a locomotion system configured to facilitate movement of the recovery mobile robot; a body comprising a compartment configured to transport a battery separate from the power supply; a first power connector disposed on the body; wherein the recovery mobile robot is configured to transfer charge to an incapacitated mobile robot, the incapacitated mobile robot having a second power connector configured to receive charge through engagement with the first power connector of the recovery mobile robot.

22. The mobile robot assistance system of claim 21, wherein the recovery mobile robot is configured to use either its own power supply or a transported battery to transfer charge to the incapacitated mobile robot.

23. The mobile robot assistance system of claim 21, wherein the power supply of the recovery mobile robot comprises a plurality of supercapacitors.

24. The mobile robot assistance system of claim 21, wherein: the recovery mobile robot comprises two first power connectors, one first power connector disposed in a front end of the body and the other first power connector disposed in a rear end of the body.

25. The mobile robot assistance system of claim 24, wherein: the two first power connectors are configured to be engageable with either of two corresponding second power connectors, one second power connector disposed in a front end of the incapacitated mobile robot and the other second power connector disposed in a rear end of the incapacitated mobile robot.

26. The mobile robot assistance system of claim 21, wherein the recovery mobile robot further comprises at least one sensor configured to facilitate alignment of the recovery mobile robot with the incapacitated mobile robot.

27. The mobile robot assistance system of claim 21, wherein: the recovery mobile robot is configured to push the incapacitated mobile robot to a location based on a determination that the incapacitated mobile robot remains incapacitated following transfer of charge.

28. The mobile robot assistance system of claim 21, wherein: each of the first power connector and the second power connector comprises a data connector for establishing a data connection and communicating data between the recovery mobile robot and the incapacitated mobile robot.

29. The mobile robot assistance system of claim 28, wherein: the recovery mobile robot transmits instructions to the incapacitated mobile robot to release its brakes through the data connection.

30. A method of assisting incapacitated mobile robots, the method comprising: by a plurality of mobile robots, moving along a plurality of pathways at a facility, the facility including a plurality of storage locations configured to store containers containing items and being accessible to the plurality of mobile robots;by a recovery mobile robot comprising a power supply, a body with a compartment configured to transport a battery separate from the power supply, and having a first power connector disposed on the body, the recovery mobile robot: moving to a location adjacent to an incapacitated mobile robot, the incapacitated mobile robot having a second power connector configured to receive charge through engagement with the first power connector of the recovery mobile robot; and transferring charge to the incapacitated mobile robot.

31. The method of claim 30, further comprising, by the recovery mobile robot, using either its own power supply or a transported battery to transfer charge to the incapacitated mobile robot.

32. The method of claim 30, wherein the power supply of the recovery mobile robot comprises a plurality of supercapacitors.

33. The method of claim 30, wherein: the recovery mobile robot comprises two first power connectors, one first power connector disposed in a front end of the body and the other first power connector disposed in a rear end of the body.

34. The method of claim 33, wherein: the two first power connectors are configured to be engageable with either of two corresponding second power connectors, one second power connector disposed in a front end of the incapacitated mobile robot and the other second power connector disposed in a rear end of the incapacitated mobile robot.

35. The method of claim 30, further comprising: receiving notification that the incapacitated mobile robot has become incapacitated; and receiving notification of a location of the incapacitated mobile robot.

36. The method of claim 30, further comprising: determining that the recovery mobile robot will transport a battery to transfer charge to the incapacitated mobile robot; and receiving the battery in the compartment.

37. The method of claim 30, further comprising: aligning the recovery mobile robot with the incapacitated mobile robot.

38. The method of claim 30, further comprising: by the recovery mobile robot, pushing the incapacitated mobile robot to a location based on a determination that the incapacitated mobile robot remains incapacitated following transfer of charge.

39. The method of claim 30, further comprising: establishing a data connection between the first power connector and the second power connector and communicating data between the recovery mobile robot and the incapacitated mobile robot.

40. The method of claim 39, further comprising: instructing the incapacitated mobile robot to release its brakes through the data connection.

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