System, apparatus and method for hi-efficiency logistic towers

Abstract

A storage system includes a three-dimensional structure including an array of cells including a plurality of cells configured to retain individual storage bins for retrieval, the array of cells forming a plurality of storage levels located at different elevations within the three-dimensional structure, respectively. A second plurality of cells positioned relative to one another to form a plurality of vertical shafts located within the three-dimensional structure. A material transfer level located beneath the plurality of storage levels, the material transfer level including a transportation system configured to move the individual storage containers to locations in the storage system. A buffer level is located above and immediately adjacent the material transfer level. The storage system includes a plurality of towerbots located atop the three-dimensional structure.

Description

System, Apparatus and Method for Hi-Efficiencv Logistic TowersBACKGROUND OF INVENTION1. Field of Invention

[0001] This invention relates generally to logistic tower-based storage systems. More specifically, at least one embodiment relates to a system, apparatus and method for Inefficiency logistic tower-based storage systems.2. Discussion of Related Art

[0002] Today, a wide variety of approaches for automation are employed in material handling logistics hubs such as distribution centers, fulfillment centers and micro-fulfillment centers. Some known approaches employ three-dimensional grid structures arranged in cells through which retrieval vehicles operate to access storage cells to either place material in a cell for storage or retrieve material stored in the cell. While a small number of these systems employ a vertical lift system, many others employ an aisle-based lift system. In the aislebased systems, a bot travels in one of two directions to move up and down an aisle and pick and place totes. These systems do not permit bot travel within the storage array in directions that are perpendicular to the direction of the aisles. Further, aisle-based systems are typically limited to a small number of storage levels because a bot designed to move along an aisle for pick and place above a certain elevation becomes too large to be practical in a high density storage system.

[0003] In some other cases, the cells are organized such that vertical columns (“elevator columns” or “elevator shafts”) are located in the structure to provide a vertical travel-path for operation of a retrieval vehicle that can access storage containers in one or more bays (or storage cells) positioned around the elevator column. In general, this type of logistics hub includes a lower level that includes a conveyor system. In these approaches, a lower level is employed to transfer material to and from a retrieval device at the bottom of the elevator shafts. That is, there is a direct exchange in real time to transfer material between the vertical lift system and the horizontal travel system. In these systems, both the vertical lift system and the horizontal travel system remain occupied with the handoff of material between the two until the handoff is completed. This leaves each of the two systems unable to perform any new or additional tasks until the handoff is complete.

[0004] In addition to the above-described problems, conventional vertical storage systemsare most often configured to only handle items having a single pre-defined configuration. For example, a vertical storage system may be designed to handle material that is stored in bins or material packed in cartons but not both. This is a result of the complexity of designing the elements of the vertical storage system to handle these two different types of storage containers. Bins tend to have a rigid structure well suited for retrieval with a hardware that locks onto the bin using any of a variety of mechanical systems. In contrast, cartons tend to have a semi-rigid structure that can be damaged when retrieved with a system designed to securely grasp rigid bins.SUMMARY OF INVENTION

[0005] Therefore, there is a need for approaches to improve the efficiency by removing bottlenecks created in conventional approaches to material transfer between a vertical material handling system and a horizontal material handling system in a logistics tower. According to some embodiments, buffer positions are included in the material handling logistics tower to remove bottlenecks. According to these embodiments, a robotic cart can directly access, retrieve and place material at the buffer positions without any direct interaction with the vertical material handling system. Further, a vertical winch-based system can also directly access, retrieve and place material at the buffer positions without any direct interaction with the horizontal material handling system. The uncoupling of the transfer from the vertical material handling system (for example, a winch-based elevator system) to the horizontal material handling system (for example, a robotic cart) provides for independent operation by the two different material handling systems. This can greatly increase the overall speed at which material is moved through the logistics tower because, for example, a vertical trolley system can complete multiple operations to move material within the storage grid after locating an item in a buffer position before the robotic cart is available to retrieve the item. Depending on circumstances, the reverse is also true. That is, a robotic cart can place an item in a buffer position and move to other tasks at the material transfer level regardless of whether the vertical retrieval system is immediately available to retrieve the item from the buffer position.

[0006] According to some embodiments, a buffer level including a plurality of buffer locations for temporary storage of items being moved within the logistics tower is located immediately adjacent the material transfer level of the system. According to one embodiment,the immediately adjacent position of the buffer level is immediately above the material transfer level.

[0007] Embodiments provide for the first time a buffer level to buffer activity and provide resilient operation that eliminates bottlenecks of activity on the material transfer level in a system that includes both: 1) towerbots for material storage and retrieval within a storage grid; and 2) robotic carts for transport at a material transfer level of the logistics tower beneath the storage grid. That is, unlike prior approaches these systems buffer “bot to bot” activity. These embodiments eliminate the bottlenecks that would otherwise occur because any transition from the vertical movement of material within the elevator columns to the horizontal movement at the material transfer level includes a handoff that must occur at the material transfer level.

[0008] For example, if a robotic cart is used, the cart is temporarily parked beneath a selected elevator column to receive material that is placed on it from above. The robotic cart remains stationary in that location blocking travel through that location by any other carts until the handoff is complete. The same is true when material is delivered to the base of an elevator column by a robotic cart for retrieval by the vertical lift system to place the item in a storage cell in the storage grid. These real-time activities can also be delayed by the ongoing operations of the vertical lift system. That is, one of the robotic cart and the vertical lift system may be required to idle at the handoff location because the other of the two material handling elements has not yet arrived for the handoff. The buffering of bot-to-bot activity in embodiments described herein eliminates the bottlenecks and the unnecessary idle time described above to greatly increase an overall efficiency and throughput of the logistics hub.

[0009] There is also a need for approaches to provide for the seamless integration of material handling for both cartons and bins in a vertical material handling system. According to various embodiments, vertical winch-based retrieval systems for handling cartons are included with conventional bin handling vertical winch-based retrieval systems. In some embodiments, the material handling logistics tower includes towerbots located atop a storage structure where some of the towerbots include retrieval systems for retrieval of bins while others of the towerbots include retrieval systems for retrieval of cartons. In various embodiments, the towerbots are self propelled for travel atop the storage structure from a first position atop a firstelevator column to a second position atop a second elevator column. According to some of these embodiments, buffer positions are also included in the material handling logistics tower.

[0010] There is also a need for a material storage system, for example, a logistics hub, including a wireless control system configured to coordinate operational states and movements of the autonomous mobile robot, vertical material handling systems, vertical handling modules, satellite bots, gridbots and mobile robots, enabling independent and asynchronous exchanges of storage containers.

[0011] As used herein with reference to material handling, the term “exchange” refers to either placing by a first material handling system an item at a second material handling system or retrieving an item by a first material handling system from a second material handling system. Those of ordinary skill in the art based on the disclosure herein will understand that an “exchange” concerns a single item that is transferred from one of the material handling systems to the other. Consequently, a single “exchange” does not require that each of the two material handling systems receive something from the other.

[0012] As used herein with reference to mobile carts or shuttles, the term “autonomous mobile robots” can refer to autonomous vehicles configured to move storage containers within a logistics hub. In some embodiments, the autonomous mobile robots can freely navigate within the footprint or external to the footprint of a structured storage grid. In other embodiments, travel of the autonomous mobile robots is restricted to travel within the footprint of a structured storage grid. In either of these approaches, the autonomous mobile robots operate on a material transfer level of the logistics hub storage system.

[0013] As used herein the term “vertical handling module” is employed to refer to a system element that is configured for vertical travel within a storage array for the handling of material stored therein. That is, a vertical handling module is configured to travel vertically within a logistics tower. Depending on the embodiment, the vertical handling module can include a material handler alone or a trolley in combination with a material handler. Further in various embodiments, the material handler can include a device such as a carton handler, a bin handler or other material handling system configured to grasp and move one or more of rigid storage containers, semi-rigid storage containers including bins, totes, cartons or storage containers having other configurations.BRIEF DESCRIPTION OF DRAWINGS

[0014] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:

[0015] FIG. 1 illustrates a perspective view of a material handling storage system including buffer positions in accordance with one embodiment;

[0016] FIG. 2 illustrates a plan view of the material handling storage system of FIG. 1;

[0017] FIG. 3 illustrates operation of a material handling storage system employed with cartons in accordance with one embodiment;

[0018] FIG. 4 illustrates another view of operation of the material storage handling system of FIG. 3 in accordance with one embodiment;

[0019] FIG. 5 illustrates still another view of operation of the material storage handling system of FIG. 3 in accordance with one embodiment;

[0020] FIG. 6 illustrates yet another view of operation of the material storage handling system of FIG. 3 in accordance with one embodiment;

[0021] FIG. 7 illustrates a gridbot employed in a material handling storage system including a buffer position in accordance with one embodiment;

[0022] FIG. 8 provides a view of details included in a gridbot operating in a first state in accordance with one embodiment;

[0023] FIG. 9 provides a view of details included in the gridbot of FIG. 8 operating in a second state in accordance with one embodiment;

[0024] FIG. 10 provides a first view of a logistics hub including buffer positions in accordance with one embodiment;

[0025] FIG. 11 provides a second view of the logistics hub of FIG. 10 in accordance with one embodiment;

[0026] FIG. 12 provides a view of a pick-station in accordance with one embodiment;

[0027] FIG. 13 provides a view of a bin handler in accordance with one embodiment;

[0028] FIG. 14 provides a view of a carton handler in a first operating state in accordance with one embodiment;

[0029] FIG. 15 provides another view of the carton handler of FIG. 14 in accordance with one embodiment;

[0030] FIG. 16 provides a view of the carton handler of FIG. 14 in a second operating state in accordance with one embodiment;

[0031] FIG. 17 provides another view of the carton handler of FIG. 14 in the second operating state in accordance with one embodiment;

[0032] FIG. 18 illustrates a satellite hot in accordance with one embodiment;

[0033] FIG. 19 illustrates a satellite hot in accordance with another embodiment;

[0034] FIG. 20 illustrates an operating mechanism for a bin handler in accordance with one embodiment;

[0035] FIG. 21 illustrates a trolley and material handler in accordance with one embodiment;

[0036] FIG. 22 illustrates a system employed to temporarily fix a position of a trolley in accordance with one embodiment; and

[0037] FIG. 23 illustrates a view of the logistics hub in accordance with one embodiment.DETAILED DESCRIPTION

[0038] This invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

[0039] FIG. 1 illustrates a perspective view of a material handling storage system 100 in accordance with various embodiments. For clarity, FIG. 1 provides a limited view of elements in the material handling storage system 100 that can be included in greater quantities in a larger material handling logistics hub at any scale. For example, the apparatus, systems and methods illustrated and described herein can be employed in a multi-level storage array system as shown and described in commonly owned U.S. patent application serial no. 18 / 460,446, entitled “System, Apparatus and Method for Hi-Efficiency Logistic Towers,” filed on September 1, 2023 (“the ‘446 application”). The disclosure of U.S. patent application serial no. 18 / 460,446 is incorporated by reference herein in its entirety.

[0040] Referring to FIG. 1, the material handling storage system 100 includes a storage grid framework 102, a plurality of vertical columns 104, a material transfer level 106, and a plurality of buffer positions, for example, a storage rack 108 located at a buffer position. The material transfer level 106 can also be referred to as a material transport level in various embodiments. The material handling storage system 100 also includes a plurality of storage bins 110, one ormore cartons 112 and a plurality of robotic carts 114. As described in greater detail below, the material handling storage system 100 provides a system configured for storage and handling of both cartons and bins in a single storage array, and in combination with buffer positions employed to increase the speed and efficiency of material handling in a material handling logistics hub.

[0041] The storage grid framework 102 is configured to define the plurality of vertical columns 104 where the columns 104 provide vertical shafts that extend from the upper level to the material transfer level 106. As described in the ‘446 application, the vertical columns can be filled with storage cells in the area above the material transfer level 106. In addition, one or more of the vertical columns are free of obstructions from an upper level of the storage grid framework 102 to the material transfer level 106 to allow travel of a vertical lift system that moves a material handling system through the storage array. That is, a material handler included in each towerbot is raised or lowered as needed to access either bins or cartons adjacent the elevator cell in which the bin handler is operating. As is described in greater detail below, when properly aligned at a desired level within the storage grid, a carriage included in the material handler extends into and out of the storage cells to place or remove either storage bins or cartons from locations within the grid. In various embodiments, each towerbot includes a material handling system designed to handle one of storage bins or cartons. As described in the ‘446 application, the towerbots can move atop the storage array to locate themselves above the various elevator columns as needed.

[0042] According to the illustrated embodiment, the material handling storage system 100 employs robotic carts 114 to move material along the material transfer level 106. This contrasts with the conveyor systems illustrated and described at the material transfer level in the ‘446 application. In general, the robotic carts operate to assist in moving bins and cartons: 1) that are newly received at the material handling storage system 100 to locations in the system accessible to the vertical lift systems for placement by the vertical lift system in a storage cell; and 2) that are placed by the vertical lift systems in locations for either transfer to a new location in the storage array or to a pickup location using the robotic carts 114. In various embodiments illustrated and described herein, the storage racks 108 located at the buffer positions provide locations accessible to each of the vertical lift systems and the robotic carts 1 14 for the transfer from one form of transport within the material handling storage system 100 to another form of transport within the system 100. As is described in greater detail herein, the robotic carts 114 are equipped with a specialized set of features that permit the handling of both bins and cartonsas well as features that allow cartons and bins to be placed at and removed from the storage rack 108 with the carts 114.

[0043] The carts 114 are referred to as “robotic” because they travel and perform operations independent of any human operator. The robotic carts 114 can also be referred to as “gridbots” because they service a storage grid. Those of skill in the art will recognize in view of the disclosure provided herein that reference to “grid” in the term “gridbot” does not imply that the direction of travel of the robotic carts or gridbots is limited in any way. For example, those of skill in the art will recognize that a gridbot is not limited to travel in two directions orthogonal to one another.

[0044] In various embodiments, a control system provided with the material handling storage system 100 (for example, as included in a larger scale multi-level storage array system) includes wireless data communication between each robotic cart 114 and a central controller. The wireless communication allows the system controller to provide instructions to individual robotic carts 114 to initiate a move from a first position to a second position along the material transfer level 106. The cart can be routed between locations in various paths of travel in depending on the embodiment. The same communication system is used to provide the instructions for operation of the robotic cart 1 14 to retrieve items (cartons and bins) from and place items on the storage racks 108 located at the buffer positions included in the buffer level 116. For example, a robotic cart 114 may receive instructions that identify a specific storage rack 108 from which a carton or storage bin needs to be retrieved. The robotic cart 114 operates with this information to travel to a location immediately beneath the buffer position, remove the item and then travel to another location in the logistics hub (for example, to deliver the item to a pick station or a transport station).

[0045] In various embodiments, a wireless control system is configured to coordinate operational states and movements of the autonomous mobile robot, vertical material handling systems, vertical handling modules, satellite bots and mobile robots, enabling independent and asynchronous exchanges of storage containers.

[0046] Referring now to FIG. 2, a plan view of the material handling storage system 100 of FIG. 1 is illustrated in accordance with one embodiment. FIG. 2 illustrates a buffer level 116 included in the material handling storage system 100. The buffer level includes a plurality of buffer positions including a plurality of storage racks 108 illustrated here and in FIG. 1. For reference, a storage rack 108 is located at the location where the carton 112 is placed (the second vertical column from the left) and each location where one of the bins 110 is placed(from the left, each of the third, fifth and sixth vertical columns). FIG. 2 also shows the relationship between the buffer level 116 and the material transfer level 106. That is, the buffer level 116 is located immediately above the material transfer level 106. As is described in greater detail below, this arrangement permits the robotic carts 114 to pull directly beneath each of the storage racks 108 to place material storage containers (cartons or bins) on or remove them from each of the buffer positions. Depending on whether they are actively transporting a material storage container, the robotic carts 114 may move laterally along the material transfer level 106 in any of four directions when located at the base of a vertical column 104.

[0047] Referring now to FIG. 3, a system 200 including a towerbot operated material-handler 220 is provided for use in the pickup and movement of cartons within a material handling logistics tower. According to the illustrated embodiment, the material handler 220 includes a trolley 222 and a carton handler 224 configured to pickup and move a carton 212. The carton handler 224 includes a carriage 226 and a frame 228 attached beneath the carriage 226. The frame includes a tray 230 suspended beneath the carriage at the lower portion of the frame. The tray 230 includes a set of slats 231 (some of which are labeled in FIG. 3) with the slats 231 spaced apart from one another with open regions located between adjacent slats 231. According to the illustrated embodiment, each slat 230 includes a smooth top surface 232 with a stop 233 located at one end. A portion of a storage rack 208 located at a buffer position is illustrated including a set of individual tines 209 that are spaced apart from one another to define the rack

[0048] In various embodiments, the trolley 222 is included as a part of a towerbot that includes a winch-based system that is employed to raise and lower material handler 220 including the trolley 222 and associated carton handler 224 vertically within an elevator column included in the system 200. According to the illustrated embodiment, the trolley 222 maintains contact with the grid framework with sets of vertically positioned wheels located at each corner of the trolley 222. To retrieve a carton located at a buffer position, the material handler 220 is lowered to a position adjacent the buffer position where the storage rack 208 is located. The carriage 226 extends horizontally above the storage rack 208 and the frame 228 is raised to place the tray 230 into engagement with the bottom of the carton 212. The carriage 226 retracts back beneath the trolley 222. This allows the winch-based system included in the associated towerbot to raise the material handler 220 to an elevation within the elevator column adjacent a selected storage cell within the logistics tower. The carriage 226 is then extended into the storage cell where the frame 228 is lowered onto a set of tines 209 located there. When thecarton is set in place in the storage cell, the carriage returns to a position beneath the trolley 222. This set of operations is reversed for retrieval of a carton from a storage cell for transport and drop off at a buffer position.

[0049] FIGS. 3-6 illustrate the series of operations performed by the material handler 220 to place the carton 212 on the storage rack 208 at the buffer position with the material handler 220 positioned adjacent the buffer position in accordance with some embodiments. FIG. 3 illustrates the start of the sequence with the material handler 220 adjacent the buffer position, the carriage 222 beneath the trolley 222 and the frame 228 in a raised position. For context, this is an operating state that can occur following a retrieval of the carton 212 from a storage cell within the logistics tower.

[0050] Referring now to FIG. 4, the carriage 226 has traveled horizontally to an extend position. This locates the frame 228 within the buffer position with the carton 212 resting on the tray 230. The slats 231 are located to engage the tines 209 because the relative positioning of slats offsets them such that they are positioned in the spaces between the tines 209. This allows the tray 230 to be moved into the buffer position without any interference between the slats 231 and the tines 209, as illustrated in FIG. 4. Further, with the frame 228 in the raised position, the carton 212 remains resting on a top surface of the tray 230. Also, the location of the stops 233 prevent the carton from sliding off the tray 230 into the elevator column in which the trolley 222 is located.

[0051] Referring to FIG. 5, the frame 228 is in a lowered position to move the tray 230 to a position that places the slats 231 at a lower elevation than the tines 209. This operation sets the carton 212 at rest on a top surface of the tines 209, that is, on the storage rack 208. In this position, the carriage can retract back beneath the trolley 222 while the carton 212 remains at rest on the storage rack 208. FIG. 5 illustrates a operating state in which the carriage is partially retracted. This is reflected by a gap 234 that now appears between the left edge of the carton 212 and the stops 232 located on the frame 228.

[0052] Referring now to FIG. 6, the carriage 226 is in a fully retracted position. This places the frame 228 including the tray 230 beneath the trolley 222. In this position, the material handler 220 is located completely within the elevator column above which the associated towerbot is parked. In this state, the towerbot can raise the material handler 220 to different elevations in the elevator cell where further pick and place operations can be performed.

[0053] In various embodiments, a material handling system 300 includes a plurality of robotic carts that navigate a material transfer level to retrieve items (cartons and bins) from andplace items at buffer positions included in the buffer level. Referring now to FIG. 7, a robotic cart 240 is illustrated for use with a material handling system (100, 200) in accordance with some embodiments. In FIG. 7, two storage racks 208A and 208B located at separate buffer positions are identified for reference although additional buffer positions and storage racks appear in the background. All the illustrated buffer positions are located in a single buffer level that is immediately above the material transfer level at which the robotic carts 240 travel. According to the illustrated embodiment, the robotic cart 240 includes a plurality of sets of wheels (including a first set of wheels 242 and a second set of wheels 243), a chassis 244 and a shelf 246 formed by a plurality of individual rails 248 each having a top surface 250. In FIG 7, a carton 212 rests at a first storage rack 208 A.

[0054] The sets of wheels, for example, the first and second sets of wheels 242, 243, are located on each of the four separate sides of the chassis 244, respectively. According to the illustrated embodiment, a third set of wheels (not shown) are located on the side of the chassis opposite the first set of wheels 242, and a fourth set of wheels (refer to FIG. 8 and wheel 245 included in the fourth set) are located on the side of the chassis 244 opposite the second set of wheels 243. This arrangement allows two sets of wheels located on opposite sides of the chassis from one another to propel the robotic cart 240 is a first direction while the remaining two sets of wheels located on opposite sides of the chassis from one another operate to propel the robotic cart 240 in a second direction perpendicular to the first direction. Because the material handling system 300 has a grid-based overall structure, this arrangement allows the robotic cart 240 to move along all four axes of the material transfer level of the system 300 (for example, each of the north-south-east-west directions). Each set of wheels includes a drive system (not illustrated) including a motor and drive linkage to connect the motor to the wheels included in the sets of wheels 242, 243.

[0055] According to the illustrated embodiment, the first set of wheels 241 (and the associated second set of wheels on the opposite side of the cart) are at a fixed elevation. That is, these fixed-elevation sets of wheels are not raised or lowered. However, the second set of wheels 243 and the fourth set of wheels 245 are employed in combination with an elevating mechanism within the cart 240 that operates to deploy these two sets of wheels as described below.

[0056] When the second and fourth sets of wheels 243, 245 are not deployed, the first 241 and third (not shown) sets of wheels are engaged with the travel surface of the material transfer level 206. Depending on the embodiment, the travel surface can be a relatively uninterruptedsmooth surface (for example, a raised floor), or it can include tracks or guide rails on which the robotic cart 240 moves. In this state, the robotic cart is free to move in a direction perpendicular to the front of the buffer positions, for example, the storage rack 208 A. However, according to these embodiments, the second and fourth sets of wheels 243, 245 must be deployed for the cart 240 to travel beneath a buffer position. According to some embodiments, the material transfer level includes a shuttle grid is formed of a network of rails or configured in a grid- like arrangement or a plurality of rail tiles that are situated adjacent to another. The rails include grooves that define a track for the wheels of a robotic carts to traverse. According to one embodiment, the travel surface includes grooves spaced and aligned such that a first pair of grooves parallel to one another receive the first 241 and third sets of wheels and a second pair of grooves parallel to one another but perpendicular to the first set of grooves receive the second 243 and the fourth 245 sets of wheels.

[0057] In general, the second and fourth sets of wheels 243, 245 are operated in one of three states. A first state in which the wheels 243, 245 are not deployed. In this state, the two sets of wheels 243, 245 are stored within the profile of the chassis 244. That is, they do not extend beneath a bottom of the cart 240. This permits the robotic cart 240 to travel under power of the first and third sets of wheels in the direction perpendicular to the open ends of the storage racks 208 located at the buffer positions. In a second state, the wheels 243, 245 are partially deployed. In this state, the wheels 243, 245 are placed in contact with the material transfer level 206 and the chassis 244 of the cart is elevated such that the first and third set of wheels are no longer in contact with the material transfer level 206. This allows the robotic cart to move in a direction into and out of the buffer locations under power of the wheels 243, 245. In a third state, the wheels 243, 245 are fully deployed. In this state, the wheels 243, 245 are lowered a greater distance beneath the cart 240. This further elevates the chassis 244 of the cart for use in placing items on or removing items from the storage racks 208. The third state also allows the robotic cart to move in a direction into and out of the buffer locations under power of the wheels 243, 245.

[0058] Referring now to FIGS. 8 and 9, the above-described operations are described in greater detail. Each of the FIGS. 8 and 9 include a rightmost image including the storage racks 208A and 208B with the robotic cart 240 located beneath and immediately adjacent a first buffer position where the first storage rack 208A is located. In the rightmost image, a carton or bin is not located on either of the illustrated storage racks 208 A and 208B. Each of FIGS. 8 and 9 include a leftmost image that provides a front view of the robotic cart 240 located beneathand immediately adjacent the first storage rack 208 A with a material storage item 252 located on the storage rack 208A. In various embodiments, the material storage item 252 can be either a carton or a storage bin (sometimes referred to as a “tote”). Each of the FIGS. 8 and 9 also include a rightmost image including the storage racks 208A and 208B with the robotic cart 240 located as illustrated in the corresponding leftmost figure but with the carton removed for clarity. In FIG. 8, the sets of wheels 243 and 245 are in a partially deployed state referred to as the second state as originally described above with reference to FIG 7. In FIG. 9, the sets of wheels 243 and 245 are in a fully deployed state referred to as the third state as originally described above.

[0059] The front view in FIG. 8 illustrates the second set of wheels 243 and a third set of wheels 245 lowered into engagement with the travel surface. With the second and third sets of wheels 243, 245 partially deployed as shown in FIG. 8, the chassis 244 is raised upward above any potential interference with the travel surface. Operation of the drive system to rotate the sets of wheels 243, 245 provides travel in a direction (forward and back) parallel to the two sets of wheels 243, 245. For clarity, this direction of travel is perpendicular to the longitudinal axis of the axles that connect opposing pairs of wheels in the two sets 243, 245.

[0060] The front view also provides a plan view of the structure provided by the tines 209 that define the storage racks 208 located at the buffer positions, and the rails 248 that include the top surface 250. For clarity, only the rightmost rail 248 is identified along with the corresponding top surface 250. However, a plurality of rails are illustrated that include the same overall structure. In the illustrated embodiment, it is the combination of rails with associated surfaces 250 that define the shelf 246 provided by the cart 240.

[0061] In various embodiments, space is provided to separate adjacent rails 248 from one another. Further, an offset is provided between the position of the plurality of rails 248 and the position of the plurality of tines 209 with the robotic cart 240 positioned beneath the buffer position 208A. This offset permits the cart to drive beneath the storage racks without any interference between the rails 248 included in the cart 240 and the tines 209. In more detail, each tine 209 includes a longitudinal axis and each rail 248 includes a longitudinal axis, respectively. Thus, in the illustrated embodiment, this arrangement positions the longitudinal axis of each rail 248 parallel to and substantially in a central location between adjacent tines included in the plurality of tines 209. In addition to the preceding, the system 300 can include dimensions and spacing that position the top surfaces 250 below a bottom of the tines 209 withthe wheels partially deployed in the second state. This also permits the cart 240 to move beneath a buffer position without interference.

[0062] Each material storage item 252 includes a bottom surface 254 that rests on a top surface of the tines 209 when the item is temporarily stored at a buffer position. With the robotic cart 240 properly aligned in front of the storage rack 208A, the alignment of the rails 248 with the tines 209 is as illustrated in FIGS. 8 and 9. With this alignment, the cart 240 can pull beneath the storage rack 208A without interference with the material storage item 252 provided that the elevation of the top surface 250 of the rails is lower than the elevation of the bottom surface 254 of the item 252, for example, as illustrated in FIG. 8.

[0063] FIG. 9 illustrates operation of the robotic cart 240 with the sets of wheels 243, 245 fully deployed in the third state. In this state, the top surfaces 250 of the rails 248 are raised to an elevation that is greater than an uppermost elevation of the storage rack formed by the plurality of tines 209. As illustrated in FIG. 9, this permits the cart 240 to move beneath the buffer position without interference with the material storage item 252 resting on the shelf 246 formed by the plurality of individual rails 248.

[0064] The separate operations of the robotic cart 240 are now described for the separate operations of removing material storage items 252 from a storge rack 208 and delivering material storage items 252 to a storage rack 208 in accordance with the embodiments illustrated by FIGS. 8 and 9. In one embodiment, the material storage item 252 is located on the storage rack 208 A provided at that buffer position. This condition occurs, for example, after the item 252 is separately delivered to the storage rack 208A by a vertical material handling system (for example, a winch-based elevator system). The cart 240 navigates a travel aisle to the front of the storage rack 208 A, for example, as propelled by the first set of wheels 241 and the second set of wheels (not illustrated). The second set of wheels 243 and the third set of wheels 245 are deployed with an elevating mechanism included in the cart 240 such that the wheels 243, 245 are engaged with the travel surface and the chassis 244 is raised upward. This removes the remaining two sets of wheels including the first set of wheels 241 from engagement with the travel surface. The cart 240 then travels into the area immediately below the storage rack 208A with the rails 248 in positions that are offset from the position of the tines 209. With the cart 240 parked beneath the rack in this location, the elevating mechanism operates again to further deploy the two sets of wheels 243, 245 and raise the chassis 244 and the rails 248 upward.

[0065] This further deployment illustrated in FIG. 9 elevates the top surface 250 of the rails into engagement with the bottom surface 254 of the item 252 to raise the item 252 above therack defined by the plurality of tines 209. The cart 240 is now free to move out from beneath the buffer position 208 A propelled by the two sets of wheels 243, 245. When the robotic cart is moved into the aisle in front of the storage rack 208A. The elevating mechanism operates to return the two sets of wheels 243, 245 to the first state in which these two sets of wheels are stored within the profile of the chassis 244. This places the other two sets of wheels, for example, the first set of wheels 241 back into contact with the travel surface. The robotic cart 240 is now free to navigate to another location in the logistics hub, for example, to bring the item 252 to a pick station.

[0066] A similar set of operations are completed to ingest a material storage item 252 into the storage grid. That is, a robotic cart travels on the material transfer level 206 to move into position in front of a buffer position. The two sets of wheels 243, 245 are then fully deployed to place the cart in the third state and elevate the item 252 above an uppermost elevation of the storage rack 208 as defined by the top surface of the plurality of tines 209. The two sets of wheels 243, 245 propel the cart 240 beneath the storage rack 208. The operations to set the item 252 on the storage rack 208 include operating the elevating mechanism to raise the wheels into the second state. This lowers the elevation of the top surface 250 of the rails 248 to an elevation lower than an elevation of the underside of the tines 209, for example, as illustrated in FIG. 8. The item 252 is set on a top surface of the storage rack 208. The cart 240 can now back out into the aisle from beneath the storage rack 208 under power of the wheels 243, 245. Now, the elevating mechanism is further operated to raise the wheels into the first state storing these wheels above the bottom of the chassis 244 and placing the other two sets of wheels, for example, the first set of wheels 241 back into contact with the travel surface.

[0067] The vertical material handling system (for example, a winch-based elevator system) is lowered by the associated towerbot to a location adjacent the storage rack 208. The material handler operates to grip the item 252 and return it to a position beneath the trolley within the elevator column. The towerbot is now raised as needed to access a storage cell above the buffer level 116 into which the item 252 is placed. In various embodiments, with the towerbot properly aligned at a desired level within the storage grid, the carriage included extends the material handler into and out of the storage cells to place the material storage items 252 (bins or cartons) in a selected location within the grid.

[0068] As described above, the sets of cells in a storage grid included in a logistics hub can be provided in a variety of configurations designed to maximize efficiency. Referring now to FIG. 10, a logistics hub 500 is illustrated in accordance with various embodiments. In someembodiments, elements shown and described with reference to the material handling storage system 100 are integrated in the logistics hub 500 at scale. The logistics hub 500 includes a set of cells, including storage cells, defined by a storage grid framework 502. These can include columns for example, the plurality of vertical columns 104 illustrated in FIG. 1 and a plurality of storage levels 505. The logistics hub 500 also includes a material transfer level 506 and a buffer level 516 that is in a region beneath the storage grid framework 502. According to the illustrated embodiment, the material transfer level 506 is located immediately adjacent and below the buffer level in the region beneath the storage grid framework 502. Racks 508 are positioned at locations at the buffer level 516 where they are used as transfer locations for the handoff of material storage items such as bins or cartons between a vertical lift system and robotic carts 540. According to the illustrated embodiment, the logistics hub 500 also includes a conveyor system 558 and pick stations 560.

[0069] Embodiments of the logistics hub 500 are employed to receive, handle, process, store and ship material using either or both of bins 510 and cartons 512. In general, the pick-stations 560 operate within the logistics hub system 500 as a point of entry or exit for material that is stored at the hub 500. In various embodiments, material is received and transported from the pick stations 560 on the robotic carts 540 to a location beneath the storage grid framework 502 for transfer to the vertical lift systems which places the material storage item within the storage grid. The material storage item is later removed using the vertical lift system lowered to the buffer level for a pickup by a robotic cart, or alternatively, placed directly on a cart for transport to the pick stations 560. From there the stored items can be sorted or packed if needed to prepare the material for shipment.

[0070] FIG. 11 provides a second view of the logistics hub of FIG. 10 in accordance with an embodiment that includes mobile towerbots 562A, 562B, 562C. In various embodiments, the towerbots 562 are self-contained mobile systems that can move horizontally across the upper level of the storage grid 501 to locate above different columns. The ability to dynamically relocate towerbots 562 can reduce the total quantity of towerbots required in the system 500.

[0071] The overall structure of the logistics hub 500 includes a plurality of vertical elevator columns, for example, a vertical elevator column 564, located in the storage grid 501. The storage grid 501 is such that the elevator columns extend from the top of the storage grid 501 to the material transfer level 506. The storage grid 501 also includes storage cells configured to retain material storage items such as the bins 510 or cartons 512. In addition, a single buffer position 566 is identified from among a plurality of buffer positions includes at the buffer level,where each buffer position includes a rack. Each towerbot 562 includes a winch system, and a material handler. In addition, each towerbot 562 includes sets of wheels and a motor operated drive system to provide power to the sets of wheels. Each towerbot 562 is in communication with a central control system which communicates data including operating instructions to the towerbots 562. The operating instructions provide the information needed for the towerbot 562 to coordinate its activities in the logistics hub 500 to move the material storage items within the storage grid 501. In various embodiments, the top of the storage grid 501 includes a set tracks configured for travel by the wheels of the towerbots as they travel between locations atop the storage grid 501. The tracks are laid out in a grid pattern with intersections at regular intervals to allow the towerbots 562 to travel in any of multiple directions. According to one embodiment, the tracks are formed as an integral part of the structural elements of an upper level at the top of the storage grid 501

[0072] In operation, the towerbots 562 navigate across the top of the grid 501 to position themselves above an elevator column 564 that is located adjacent a selected storage cell or buffer position. If a material storage item 510, 512, 552 is being received into the storage grid 501, the towerbot 562 lowers a vertical lift system down the elevator column 564 to, for example, retrieve a carton 512 or bin 510 from a storage rack located on the buffer level. The vertical lift system deploys a material handler to reach into the buffer location, retrieve the item and withdraw back into the elevator column. The towerbot then operates the lift system to raise the trolley and locate the associated material handler adjacent a storage cell in which the item is placed for storage. According to some embodiments, the storage cells include double deep configurations provided in the storage grid 501. In these double deep configurations, the carriage included in the material handler can extend thru a storage cell immediately adjacent the elevator cell in which the material handler is located to access the storage cell that is onecell removed from the elevator column.

[0073] The towerbots 562 described above move between locations along the top of storage grid 501 without a load. That is, without carrying a material storage item. However, in alternate embodiments, the towerbots 562 have the headroom necessary to draw the material storage items within the towerbot frame and then move between locations along the top of the storage grid 501.

[0074] Because the elevator columns 564 are included in an interior of the storage grid 501, buffer positions are also located within the interior of the storage grid 501. That is, unlike prior approaches, the buffer positions are not limited to on-aisle locations. Buffer positions are alsonot limited to only the outer edges of the storage grid 501. Also, unlike prior approaches the buffer positions are directly accessible to a vertical lift system. Depending on the embodiment, these can include a single deep or a double deep arrangement of the storage cells. Further, the logistics hub 500 illustrated in FIG. 11 permits travel by the robotic carts 540 in at least four directions. This provides greater operational flexibility and efficiency than aisle-based configurations because the robotic carts 240 have a greater freedom of movement and because they can travel beneath the entire storage grid.

[0075] Referring now to FIG. 12, a material handling system 600 including a pick station 660 is illustrated in accordance with various embodiments. The pick station 660 includes a lower level 668, an upper level 670, a first end 672 and a second end 674. The pick station is designed with a pass-through design that allows a robotic cart 640 to travel on the lower level 668 beneath the upper level 670, entering at the first end 672 in the direction of arrow A and exiting at the second end 674 in the direction of arrow B. According to the illustrated embodiment, the upper level 670 includes a rack with a plurality of tines at each of the first end 672 and the second end 674. In some embodiments, the lower level 668 is included in the material transfer level 606 of the overall logistics hub.

[0076] The features included in the illustrated embodiment, allow the robotic cart 640 designed as shown and described herein with reference to the carts 240, to pause beneath either end and deploy the wheels of the cart to place the cart in the third state described with reference to FIGS. 8 and 9. This operation locates the rails of the cart between the tines included at the pick station and raises the top surface of the rails into engagement with the bottom surface of the material storage item located at the first end 672. When this operation takes place at the first end 672, a robotic cart 240 loaded with a material storage item delivers that material storage item to the pick station 660, for example, placing the storage bin 610A at the location illustrated in FIG. 12. The empty robotic cart 640 then travels along the lower level 668 to the second end 674 where is pauses and again fully deploys the wheels in the third state to place the tops of the rails into contact with the material storage item, for example, the storage bin 610B. This raises the material storage item off the rack and allows the cart 640 to move out from beneath the upper level.

[0077] Referring now to FIG. 13, a view of a system 700 is illustrated in accordance with one embodiment including a bin handler 776 for placing and retrieving storage bins 712 within a storage grid of a logistics hub. According to the illustrated embodiment, the bin handler 776 includes a first extension 778, a second extension 780, an actuator 782, a pair oflift arms 784 and a locking system 786. In some embodiments, the bin handler 776 is configured for operating in a storage grid that includes pairs of double deep storage cells, for example, as illustrated in FIG. 13. In various embodiments, the bin handler 776 is included in a vertical lift system with a towerbot and a winch-based system that is employed to raise and lower the trolley 722 and associated bin handler 776 vertically within an elevator column included in the system 700.

[0078] In some embodiments, the pair of lift arms include a first lift arm seen in the view presented in FIG. 13, and a second lift arm located on the side of the bin handler opposite the first lift arm. The actuator 782 is coupled to the lift arms 784. Further, the locking system 786 can include a solenoid and associated locking pin located at each of the four comers of the bin handler 776, respectively.

[0079] In operation, the bin handler 776 operates the locking system 786 to temporarily secure each of the locking pins into engagement with a rim of the storage bin 712 once the carriage included in the bin handler 776 is extended into a storage cell. For example, operation of the respective solenoids moves the associated locking pin into secure engagement with the storage bin 712. With the storage bin 712 securely held by the bin handler 776, the actuator 782 operates to move the lift arms upward, for example, using a rack and pinion mechanism. This raises the storage bin 712 above the rack so that it can be pulled into the elevator cell. The towerbot now operates to raise the bin handler 776 including the storage bin 712 to a location where it is transferred into a storage cell location accessible from the elevator column in which the bin handler 776 is located.

[0080] Referring now to FIGS. 14 and 15, a carton handler 824 is illustrated in accordance with another embodiment. The carton handler 824 includes a carriage 826 and a collapsible frame 828 attached to the carriage 826. The frame 828 includes a plurality of telescoping legs 887 that connect a tray 830 to the carriage 826. The tray 830 includes a plurality of blades 831 including inner blades 825, a first outer blade 827, and a second outer blade 829. The plurality of blades 831 are spaced apart from one another with open regions located on either side and immediately adjacent to each of the inner blades 825. According to the illustrated embodiment, each of the blades 831 included includes a smooth top surface 832 with a stop 833 located at one end. The carton handler 824 also includes a pair of extenders of which a single extender 888A is illustrated in FIG. 14. The two extenders are located on opposite sides of the carton handler 824 from one another. The two sides on which the extenders 888 are located are those that are perpendicular to the front of the carton handler 824. A proximal end (or upper region)of each of the telescoping legs 887 and the plurality of extenders 888, respectively, is attached to the carriage 826. A distal end (or bottom region) of each of the telescoping legs 887 and the plurality of extenders 888, respectively, is attached to a one of the outer blades 825, 829. This places the telescoping legs 887 and the plurality of extenders 888, respectively, on the sides of the carton handler 824 that extend from a front of the carton handler to a rear of the carton handler. In addition, this places a distal end of one of the telescoping legs in each one of the four comers, respectively, of the tray 830. In FIGS. 15-17, a fourth of the four telescoping legs is obscured from view by the second telescoping leg 887B.

[0081] The carton handler 824 also includes a vision system 889 (FIG. 14) and a motor 890 (FIG. 15). In various embodiments, the vision system 889 includes imaging equipment, for example, a camera to capture still images and / or video of an item located in the tray 828. In various embodiments, information provided by the vision system 889 is employed in itemidentification (for example, for capturing images of barcodes or labels located on cartons) and / or to determine a condition of an item that is received on the tray 828 (for example, to determine whether a carton is damaged).

[0082] In various embodiments, the motor 890 illustrated in FIG. 15 is employed to operate the extenders 888 which lower and raise the tray 830. For example, the motor 890 and a horizontal drive shaft can be located within the carriage 826. As is described in greater detail below, this drive system rotates pinion gears that are included in an operating mechanism to extend and retract the plurality of extenders 888. The carton handler 824 operates to extend and retract the frame 828 between a storage position illustrated in FIGS. 14 and 15 and a fully open position as illustrated in FIG. 16. As explained below, the extenders 888 may also be placed in one or more intermediate positions between the storage position and the fully open position.

[0083] FIG. 16 illustrates an operating mechanism 891 A connected to the first extender 888A located on a first side of the carriage 826. A corresponding operating mechanism (not illustrated) is located on the opposite side of the carriage 826 where it is connected to the second extender 888B. According to the illustrated embodiment, each of the operating mechanisms 891 includes a pinon gear 892 and a drive rack 893. The pinion gears are connected to a drive shaft (not illustrated) operated by the motor 890. In one embodiment, the drive shaft is located horizontally to span the width of the carton handler 824. According to some embodiments, each extender 888 includes a left and right moveable linkage with the left linkage connected to the drive rack 893 at a first axis A and a right linkage connected to the drive rack 893 at a secondaxis B. In FIG. 16, the two axes A, B are separated by a separation distance X. The drive rack 893 on each side is connected to the top of the corresponding extender 888A and travels horizontally in response to a rotation of the pinion gear 892. According to the illustrated embodiment, the right linkage is attached in a stationary location at the second axis B while the left linkage is directly attached to the drive rack at the axis A. This allows the axis A to travel with the motion of the drive rack 893. By displacing the horizontal location of the axis A, the horizontal travel of the drive rack 893 is translated to a change in a separation distance X.

[0084] In the illustrated embodiment, the separation distance X between a location of the first axis A and the second axis B is greatest with the carton handler 824 in the fully retracted position. In the fully open position illustrated in FIG. 16, the plurality of extenders 888A, 888B travel (with the moveable linkages) to the fully extended position with the separation distance X reduced to a minimum. In these embodiments, the telescoping legs 887 also increase in length between a minimum length when the carton handler 824 is in the fully retracted position and a maximum length when the carton handler 824 is in the fully open position. According to the illustrated embodiment, each of the telescoping legs 887 includes a base 894 and a plurality of moveable sections 895. In FIG. 16, the elements included in each of the telescoping legs 887 are called out with reference characters for the third telescoping leg 887C. However, these are representative for all four of the telescoping legs.

[0085] These embodiments are advantageous for multiple reasons. For example, the carton handler 824 can be tucked beneath the trolley in a compact storage position. This reduces the moment of the frame 828 with the carton handler 824 empty relative embodiments that fix the frame in a position that is extended further beneath the trolley when empty. That is, the mass of the frame 828 is drawn right up beneath and adjacent to the trolley rather than being extended away from it. This reduces the length of the lever arm that connects the tray 830 to the carriage 826. Further, as is described below with reference to FIG. 17, the adjustable vertical displacement of the tray 830 also supports designs that better assist in securing cartons within the carton handler 824. Each of these features facilitate the rapid vertical travel made possible with the winch-based towerbot system because they can reduce the sway of the frame beneath the carriage and eliminate possible movement of carton’s located on the carton handler 824 as the carton is being raised or lowered by the towerbot.

[0086] Referring to FIG. 17, a carton handler 824 is illustrated with a first carton 812A and a second carton 812B received on the tray. The cartons 812A, 812B rest on the plurality ofblades 831. In the illustrated embodiment, the cartons 812A, 812B are wide enough that they rest on the top surface, for example, the top surface 832, of each of the inner blades 825, the first outer blade 827 and the second outer blade 829. Those of ordinary skill in the art will recognize based on the disclosure provided herein that a narrower carton may only be received on only some of the plurality of blades 831. Here, the extenders 888 are located in their fully extended position. This position is employed during the pickup or drop-off of one or more cartons transported by a material handler.

[0087] Embodiments of the system illustrated herein can include a travel mode that allows one or more cartons to be pressed between an underside of the carriage 826 and the surface of the tray 830. This can assist in temporarily securing a carton within the carton handler 824 without damage to the carton(s) while the loaded carriage is traveling within an elevator column (that is, while the loaded carriage is raised or lowered). According to some embodiments, a diffuse sensor is located in or on an underside of the carriage 826 facing downward. In these embodiments, the diffuse sensor employs optical proximity sensing to determine when the carton(s) are engaged with the underside of the carriage. According to other embodiments, a pressure sensitive switch sensitive to mechanical displacement is positioned to engage the top of a carton secured between an underside of the carriage and the top surface of the tray 830. In various embodiments, an adjustment of a gap between an underside of the carriage and the top surface of the tray 830 (and degree of force applied) is controlled by the movement of the extenders 888 up or down as driven by the operating mechanism 891.

[0088] In operation, the towerbot lowers a material handler including a trolley with the associated carton handler 224 within an elevator column to align with a location of a buffer position or storage cell at which the cartons 812A, 812B are to be placed in or removed from. The empty-travel position illustrated in FIGS. 14 and 15 is employed to move the empty material handler into position with the frame 828 drawn right up beneath and adjacent to the trolley. The operating mechanism 891 operates to move the extenders 888 to a fully extended position with the telescoping legs 887 extending with the travel of tray 830 moving downward by the extenders 888. The carriage 826 travels into the location to extend the blades within the buffer position or storage cell. The blades 831 are aligned so they are located adjacent to the tines included at the location. If the cartons are being retrieved from a buffer position or storage cell, the operating mechanism 891, powered by the motor 890, operates to raise the tray 830 such that the plurality of blades 831 are placed into engagement with an underside of the cartons812A, 812B to lift the cartons off of the rack located in the buffer position or storage cell. The carriage 826 travels rearward into vertical elevator column beneath the trolley. From there, the trolley is raised or lowered by the towerbot to a location adjacent to the elevator column where the cartons 812A, 812B are placed (or dropped off).

[0089] An operation to set cartons 812A, 812B transported for drop off includes some steps that are a reverse of that described for a carton pickup. Here, the carriage 826 travels forward into the buffer position or the storage cell where the cartons 812A, 812B are to be placed. The operating mechanism 891 moves the extenders from a travel position in which the cartons 812A, 812B are temporarily secured in the carton handler 824 to an extended position in which the top surface of the tray 830 is beneath a top surface of the rack where the cartons 812A, 812B are being placed. This allows the underside of the cartons 812A and 812B to rest on the top surface of the rack. The carriage 826 is retracted beneath the trolley. The frame 828 collapses into a fully retracted mode as illustrated in FIGS. 14 and 15. The elevation of the trolley is then adjusted by the towerbot as the trolley travels with the carriage through the vertical elevator column to place it adjacent a buffer position or storage cell where additional items can be picked up.

[0090] FIG. 17 illustrates two cartons located on the tray 830 formed by the plurality of blades 831. According to some further embodiments, a system provides a precise control of operation of the carriage 826 such that a single carton can be picked or placed even where multiple cartons are located at or being positioned at a buffer position or storage cell. That is, the horizontal travel of the carriage 826 is controlled to limit a depth of penetration into these locations. This allows for a selection of only one of multiple cartons the carton handler 824 being picked up. It also allows the carton handler 824 to place only one of multiple cartons 812A, 812B at a location. Referring to the embodiment illustrated in FIG. 17, for example, the carton handler 824 can partially extend the carriage 826 and frame 828 into a buffer position or storage cell. The operating mechanism 891 can control the elevation of the try to set only the first carton 812A at the location.

[0091] FIG. 17 also illustrates a set of wheels 894 included in the carriage 826. A corresponding set of wheels is located on the opposite side but obscured by the carriage frame in this view. In some embodiments, the set of wheels 894 on each side only include idler wheels. In these embodiments, a chain or belt drive system is engaged with the carriage to provide the motive force used to move the carriage horizontally extending the tray 830 into a buffer position or storage cell and withdrawing the tray 830 back beneath the trolley. Accordingto another embodiment, one or more of the plurality of wheels 894 is powered to provide the force for the horizontal travel of the carriage 826. In various embodiments, the wheels 894 travel on tracks located at the buffer position or storage cell.

[0092] In some embodiments, the material handler includes the trolley suspended beneath the towerbot and a carton handler in the form of a bot secured beneath the trolley. In these embodiments, the carton handling bot is not tethered to the trolley as it travels horizontally into a storage cell or a buffer position. Instead, the carton-handling bot includes a power source to allow it to travel under its own power into a buffer position or storage cell and return back beneath the trolley during various operations. These embodiments allow for the carton handler 824 including the carriage 826 and the frame 828 including the tray 830 to decouple from the trolley. These embodiments also allow a storage cell to act as a temporary storage position for the carton-handling bot. That is, the carton-handling bot can park itself in a storage cell while disconnected from the trolley. The trolley then moves vertically within an elevator column under control of a towerbot but independent of the carton-handling bot. These embodiments provide a variety of different benefits including allowing for maintenance (or a temporary retirement) of a carton-handling bot in need of service and a switch to a different cartonhandling bot stored at another position adj cent the vertical elevator cell in which the trolley is operating.

[0093] In accordance with some embodiments, a logistics hub (for example, the logistics hub 500, or the logistics hub 1000 described below) includes two styles of tower bots. These include a first type of tower bot with a material handler configured for picking-up, transporting and dropping off bins and, a second type of tower bot with a material handler configured for picking-up, transporting and dropping off cartons. Both types of towerbots can be included atop the logistics hub where the instructions communicated to the tower bots direct them to handle the matching item of material storage (either a bin or a carton, respectively). In a further embodiment, these systems can include two types of independent material handling bots that can couple to a trolley. For example, these can include an independently powered carton-handling bot as described above with reference to FIG. 17.

[0094] These embodiments also include independently powered bin-handling bots. The bin-handling bots include a carriage and hardware designed to securely grip a storage bin. In addition, with the trolley positioned to locate the bin-handling bot adjacent to a storage cell, these embodiments allow the bin handling bot to drive from beneath the trolley into a storage cell while disconnected from the trolley. The trolley is then free to move vertically within anelevator column under control of a towerbot but independent of the bin-handling bot. These embodiments provide similar benefits to those described above for the carton-handling bot including allowing for maintenance (or a temporary retirement) of a bin-handling bot in need of service and a switch to a different bin-handling bot stored at another position adjacent the vertical elevator cell in which the trolley is operating. In addition, in systems that include both independently powered bin-handling bots and independently powered carton-handling bots, a single type of tower bot can be employed. That is, a combination tower bot and trolley can retrieve a selected type of independently powered bot based on a specific task or set of tasks that it is scheduled to perform (either the handling of bins or the handling of cartons). The trolley is parked beside a storage location that includes the correct type of bot. The bot drives itself into engagement with the trolley. The towerbot is then free to raise and lower the trolley to pick-up, transport and drop off the type of material storage item that matches the style of the bot. The towerbot is also free to raise the trolley into the tower bot frame and navigate to a different vertical elevator column to perform additional tasks. The bot can be switched out with the other style bot as needed to perform a set of additional tasks on the other type of material storage item.

[0095] Referring now to FIG. 18, a satellite bot 1810 is illustrated in accordance with various embodiments. In general, a satellite bot is a self-powered bot that is parked within a material handler that is coupled to trolley. The trolley is raised and lowered within a storage array system by a towerbot. A difference between these embodiments and most of the embodiments described above, is that the satellite bots are self propelled. As is described in further detail below, this allows the satellite bot to drive untethered from the material handler to within a storage cell and back again. Depending on the embodiment, a satellite bot can engage with and move either cartons, bins or both cartons and bins.

[0096] The embodiment of the satellite bot 1810 illustrated in FIG. 18, shows a carriage 1826 that houses an energy storage system 1831, a drive motor 1833, a power converter 1835, a processing system 1837, a first drive belt 1838, a second drive belt 1839, a winch 1841, and a lift motor 1843. A tray 1830 is connected to the carriage 1826 by a first extender 1888A and a second extender 1888B located on the opposite side of the carriage 1826. According to the illustrated embodiment, a pair of lift wires 1845A and 1845B also connect the tray 1830 to thecarriage 1826. According to the illustrated embodiment, the tray 1830 includes a set of tines that are arranged to allow an interference-free engagement with storage racks.

[0097] In operation, the satellite bot 1810 connects to an external source of power when it is parked within a material handler to store energy in the energy storage system 1831. According to some embodiments, the energy storage system 1831 includes one or more supercapacitors. In another embodiment, a battery, for example a lithium-ion battery is included in the energy storage system 1831. The power converter 1835 is employed to convert power received from the external source of power to a voltage suitable for use by the satellite bot 1810. The processing system 1837 provides for autonomous control of the satellite bot 1810, for example, as it navigates back and forth between the material handler and the storage cells to pickup and to place storage containers. In various embodiments, the processing system 1837 includes a wireless communication system for communication between the satellite bot 1810 and the central controller for the storage array system.

[0098] Propulsion is provided by a drive system that includes two separate belt drive systems that each include a drive motor coupled to a drive wheel to move a belt (or track). In FIG. 18, the drive wheels and one of the two drive motors are obscured. However, the drive motor 1833 that rotates the drive wheel associated with the first drive belt 1838 is illustrated. A similar arrangement provides the motive force to operate the second drive belt 1839. Each of the two belt drive systems includes one or more idler wheels arranged in combination with the respective drive wheel.

[0099] According to the illustrated embodiment, the tray 1830 is placed in a collapsed position when it is raised and securely stored beneath an underside of the carriage 1826. This provides the satellite bot 1810 with an overall profile like the carton handler 824 as illustrated in FIGS. 14 and 15. In operation, the tray 1830 is released and allowed to descend under the force of gravity to the fully extended position illustrated in FIG. 18. This also draws the two extenders 1888A and 1888B downward. A lift system including separate winches powered by separate lift motors operate to spool separate lift wires to raise the tray 1830 closer to an underside of the carriage 1826. For example, one of the pair of lift systems includes the lift motor 1843, the winch 1841, and the lift wire 1845B. The lift wire 1845 A also appears in FIG. 18, however, the associated lift motor and winch are partially obscured from view. As the tray descends, the lift wires unwind from the winches. The processing system 1837 can be used to control the rewinding of the lift wires to move the tray 1830 upward. When the tray 1830 is empty, this returns the tray to the collapsed position. However, when a storage container islocated on the tray 1830 the upward travel of the tray 1830 can be controlled to pinch or press the top surface of the storage container into engagement with an underside of the carriage 1826. This gripping force can be used to secure the storage container in place for transit of the satellite bot when travelling in a self-propelled mode. This can also be a significant benefit when the satellite bot has returned to the “home” position parked in the material handler. In this operating state, the storage container is securely held under the upward pressure provided by the tray 1830. This allows for a high-speed transit over significant vertical distances as the trolley is raised and / or lowered by the towerbot. Applicant finds that securing the storage containers for transit in this manner overcomes one of the problems that prevented prior approaches from increasing the height of a storage tower in a meaningful way. That is, travel over substantial vertical distances can slow material handling down significantly, and storage containers that are not adequately secured result in slower vertical travel. This previously prevented storage towers from increasing to the heights now available with Applicant’s approach.

[0100] According to some embodiments, the satellite bot 1810 can retrieve and move storage containers that include both cartons and bins. However, in some other embodiments, cartons are retrieved with a satellite bot that either only or primarily handles cartons while bins, for example, rigid bins, are retrieved with a satellite bot designed to only handle bins. According to further embodiments, a universal carriage assembly is provided with which different container-handling modules can be interchanged. For example, in accordance with one embodiment, the tray system illustrated in FIG. 18 is a modular assembly that can be optionally removed from the carriage 1826 and replaced with a dedicated bin handling module.

[0101] According to various embodiments, the satellite bot 1810 and other embodiments of satellite bots as described herein include a vision system (not illustrated). The vision system can include a camera or other imaging equipment employed in monitoring a positioning of the satellite bot relative to a storage container, a detection of objects within a storage container, and anomaly detection. Referring to the satellite bots 1810 and 1910 (described immediately below), the vision system can be deployed in the carriage 1826, 1926 facing downward to the region below the carriage. The vision system can be aimed downward and angled forward, that is, pointed toward the direction in which the satellite bot travels when entering a storage cell. The vision system can provide image data through wired (or in some embodiments, wireless) connection with the processing system 1837. The processing system uses the image data to control the travel of the carriage and the operation of the storagecontainer handling module (carton handler, bin handler, etc.) for a proper pickup or placement of the storage container.

[0102] When used for object detection, the vision system captures images of the contents of a carton, bin or other storage container. The image data can include bar codes or other information used to identify the type of material and quantity of material stored in the storage container. When used for anomaly detection, the image data is processed to determine the condition of the storage container and its contents. This information can be used to adjust operation of the satellite bot, for example, to avoid shipping damaged items, and to establish a priority for repair and / or replacement of damaged items.

[0103] Referring now to FIG. 19, a satellite bot 1910 including a bin handling module 1950 is illustrated in accordance with some embodiments. The bin handling module 1950 includes a set of four hooks each coupled to an operator via an arm. The embodiment illustrated in FIG. 19, includes a hook located at each of the four corners. Other arrangements of the hooks and alternate gripping hardware and mechanisms can be employed depending on the embodiment. Three of the four hooks are seen in FIG. 19 with a first hook 1951 and an associated arm 1953 labeled as a representative example. The fourth hook is obscured from view.

[0104] The hooks 1951 are sized and shaped to engage with a rim of a storage bin when the satellite bot 1910 is positioned directly above the storage bin. As is described in greater detail with reference to FIG. 20, an electrically operated operating mechanism acts to move the hooks radially inward to draw the inside surface of the hooks into engagement with the rim of the storage bin to allow the satellite bot 1910 to securely grasp the storage bin. The operating mechanism operates to move the hooks radially outward to release the storage bin on a gridbot, on a rack in a buffer level or in storage cell.

[0105] Referring now to FIG. 20 a satellite bot 2010 including a carriage 2026 and a bin handling module 2050 is illustrated from a perspective that shows features included in the operating mechanism for the bin handler. The operating mechanism includes a mechanical linkage 2055 connecting a hook 2051 to a slew ring 2063. According to the illustrated embodiment, the mechanical linkage 2055 includes a distal member 2057, a proximate member 2059 and a pivot joint 2061 connecting the distal member 2057 to the proximate member 2059. The proximate end of the hook 2051 is attached to the distal member 2057. In operation, the hook 2051 travels linearly in a radial direction and the arm 2053 remains in a fixed location to provide a track within which the hook 2051 travels. For clarity, reference is only made to thehook 2051 and associated mechanical linkage 2055. This illustrates an exemplary operation for the three other hooks and associated mechanical linkage included in the bin handling module 2050. Those of ordinary skill in the art will recognize from the disclosure provided herein that the three remaining hooks and mechanical linkages are operated in a like manner at the same time as the hook 2051 and mechanical linkage 2055 operate as described herein.

[0106] The operating mechanism is in a first state in FIG. 20. In this state, the mechanical linkage 2055 is in a fully extended position. In this position, the proximate member 2059 and the distal member 2057 are positioned to align with one another. That is, the longitudinal axis of the two members 2057, 2059 are parallel with one another. This positions the hook 2051 in a position in which it is extended radially outward a maximum distance from the central vertical axis of the satellite bot 2010 around which the slew ring 2063 rotates. The bin handling module 2050 includes a motor that operates to rotate the slew ring 2063 to change the state of the operating mechanism. For example, rotary movement of the slew ring 2063 from the position shown in FIG. 20 will move a proximate end of the proximate member 2059 in a manner that causes a rotational movement within the pivot joint 2061 and draws the proximate end of the distal member 2057 radially inward. This movement draws the hook 2051 , which is connected to the distal member 2057 radially inward. With the bin handling module 2050 centered over a bin (or “tote”) the hook 2051 grabs the rim of the bin. The corresponding action of the three remining hooks in combination with the hook 2051 allow the bin to be securely gripped by the bin handler 2050.

[0107] The hook(s) 2051 illustrate one form of gripping hardware. In this example, the gripping hardware is configured to engage and securely grip the rim of a storage bin. However, Applicant finds that other types of gripping hardware can be deployed in other material handling modules employed in combination with a carriage in alternate forms of satellite bot. These alternate embodiments can still employ a motor operated slew ring and associated linkage to operate the gripping hardware. In general, these approaches provide an operating mechanism that converts a rotary motion to a gripping force that is directed radially inward to secure the alternate forms of storage containers. This alternate gripping hardware can fit different types of storage containers, including for example, drums. Further, depending on the embodiment, the material handling module can be employed to grip rigid storage containers, semi-rigid storage containers, or pliable storage containers. In each of these embodiments, the gripping force can be precisely adjusted by controlling the amount of rotation of the slew ring. In some embodiments, a stepper motor is employed to control the rotation of the slew ring.Although the gripping force is directed radially inward in the above-described embodiments, a radially outward directed gripping force can be employed in other embodiments, for example, where the gripping hardware is located radially inward of the attachment features included in the storage container. Here too, operating hardware including a slew ring, mechanical linkage and attachment hardware such as hooks or fingers (facing in a radially outward direction) can be employed together.

[0108] Referring now to FIG. 21, a trolley 2122 equipped with a housing 2165 for storing a satellite bot 2110 is illustrated in accordance with one embodiment. In the illustrated embodiment, the satellite bot 2110 includes a carriage 2126 and a bin handler 2150. However, other configurations of the satellite bot 2110 can be employed in combination with the trolley 2122 in various embodiments, for example, a carriage and carton handling module. According to the illustrated embodiment, the housing 2165 includes a first side wall 2167, a second side wall 2169 and a top wall 2171. According to some embodiments, a rear wall (not illustrated) is also included. The walls of the housing 2165 define a storage chamber in which the satellite bot 2110 is parked when not in use, for example, as the trolley 2122 is raised and / or lowered by a towerbot within an elevator column of a storage array included in a logistics tower (or “logistics hub”).

[0109] Applicant finds that the dynamic set of forces that arise with use of an untethered, self-propelled satellite bot challenges the stability of the system hardware when suspended from a tower bot. FIG. 21 illustrates additional elements of embodiments that address these challenges. Each of the wheels (for example, the wheel 2172) used to guide and maintain the lateral alignment and overall positioning of the trolley 2122 within an elevator column is connected to an articulating arm (for example, articulating arms 2174A, 2175B, 2175C). Further, a distal end of each articulating arm includes a surface (for example, the surface 2177) that is employed in temporarily locking the trolley 2122 at a fixed location in the elevator column. According to these embodiments, the surface 2177 provides a surface that is pressed into engagement with the framework within which the trolley travels, for example, the framework or grid structure of the storage grid.

[0110] Referring now to FIG. 22, a trolley 2222 including a position-locking system is illustrated in accordance with one embodiment. According to the illustrated embodiment, the position-locking system includes a slew ring 2278, an operating linkage 2279 and an associated articulating arm 2275. A motor (not illustrated) operates to rotate the slew ring 2278. For clarity, only one of the four sets of operating linkage and articulating arms included in thetrolley are identified with reference characters. However, those of ordinary skill in the art will recognize from the disclosure provided herein that each of the wheels included in the trolley 2222 are associated with operating linkage and articulating arms that are operated in a like manner at the same time as the operating linkage 2279 and articulating arm 2275 operate as described herein.

[0111] The operating linkage 2279 includes a rigid arm 2281, an inner pivotal connection 2283, and an outer pivotal connection 2285. A proximate end of each rigid arm is pivotally connected to the slew ring 2278 at the inner pivotal connection 2283. A distal end of each rigid arm is pivotally connected to the proximate end of the associated articulating arm 2275 at the outer pivotal connection 2285. The slew ring 2278 includes a rotational axis aligned with the central vertical axis of the trolley L 1. The rotational motion of slew ring 2278 is translated into a linear travel in a radial direction of the distal end of the rigid arm 2281. This in turn, acts to move the articulating arm 2275 attached at the outer pivotal connection 2285 in a linear and radial direction of travel. The position locking system operates when the carriage is properly aligned for operation of the satellite bot to transit from the storage chamber to storage cell or buffer location. For this operation the linear force is directed in a radial outward direction to force the surface 2177 into engagement with the framework of the elevator shaft within which the trolley is located. This locking force acts to temporarily immobilize the trolley while the satellite bot is in transit. In some operations, the satellite bot navigates to place an item in a storage cell or buffer position before returning to the storage chamber. In other operations, the satellite bot navigates to retrieve an item from a storage cell or buffer position before returning to the storage chamber. In still other operations, the satellite bot navigates to a storage position in the logistics tower external to the material handling system. For example, to temporarily place the carriage out of service for routine maintenance.

[0112] Referring now to FIG. 23, a view of a logistics hub 1000 is provided in accordance with embodiments that include a plurality of aisles, see for example, the aisles A- M in FIG. 19. The logistics hub 1000 includes a plurality of mobile towerbots, for example, the tower bot 1062 that operate to move bins 1010 and / or cartons 1012 within the hub 1000 as described elsewhere herein. The logistics hub 1000 also includes vertical elevator columns, for example, the elevator column 1064, a material transfer level 1006. A plurality of robotic carts 1040 travel on the material transfer level 1006 picking up, transporting and dropping off the bins 1010 and / or cartons 1012. In various embodiments, the towerbots are self-contained mobile systems that can move horizontally across the upper level of the storage grid 1001 tolocate above different columns. The overall structure of the logistics hub 1000 includes the plurality of aisles A-M each including a plurality of vertical elevator columns located adjacent to one another. The storage grid 1001 is constructed with the elevator columns extending from the top of the storage grid 1001 to a material transfer level 1006. Depending on the embodiment, the aisles can span all or a part of the width of the storage grid 1001.

[0113] The storage grid 1001 includes storage cells configured to retain material storage items such as the bins 1010 or cartons 1012. In addition, a single buffer position 1066 is identified from among a plurality of buffer positions includes at the buffer level, where each buffer position includes a rack. Each towerbot 1062 includes a winch system, and a material handler. In addition, each towerbot 1062 includes sets of wheels and a motor operated drive system to provide power to the sets of wheels. Each towerbot 1062 is in communication with a central control system which communicates data including operating instructions to the towerbots 1062. The operating instructions provide the information needed for the towerbot 1062 to coordinate its activities in the logistics hub 1000 to move the material storage items within the storage grid 1001.

[0114] In operation, the towerbots 1062 navigate across the top of the grid 1001 to position themselves above an elevator column 1064 that is located adjacent to a selected storage cell or buffer position. If a material storage item 1010, 1012 is being received into the storage grid 1001, the towerbot 1062 lowers a vertical lift system down the elevator column 1064 to, for example, retrieve a carton 1012 or bin 1010 from a storage rack located on the buffer level. The vertical lift system deploys a material handler to reach into the buffer location, retrieve the item and withdraw back into the elevator column. The towerbot then operates the lift system to raise the trolley and locate the associated material handler adjacent to a storage cell in which the item is placed for storage. According to some embodiments, the storage cells include double deep configurations provided in the storage grid 1001. In these double deep configurations, the carriage included in the material handler can extend thru a storage cell immediately adjacent the elevator cell in which the material handler is located to access the storage cell that is onecell removed from the elevator column.

[0115] These embodiments including the aisles A-M are advantageous because they provide ready access for maintenance and service to the towerbots 1062 and to hardware included in the logistics hub 1000 but located within the interior of the storage grid 1001. The aisles can also speed the storage and retrieval of cartons 1012 and / or bins 1010 within the logistics hub because a towerbot can travel laterally between locations atop the storage grid1001 along the aisle (A-M) with a material handler suspended several levels beneath it. That is, without the need to raise the trolley and carriage to within the frame of the towerbot atop the structure while the towerbot moves from above a first elevator column in the aisle to above a second elevator column in the same aisle.

[0116] Depending on the embodiment, the logistics hub 1000 can include a single deep or a double deep arrangement of the storage cells. Further, the logistics hub 1000 illustrated in FIG. 23 permits travel by the robotic carts 1000 in at least four directions. This provides greater operational flexibility and efficiency because the robotic carts 1040 have a greater freedom of movement and because they can travel beneath the entire storage grid.

[0117] Although the embodiments that are illustrated and described above illustrate material handlers that are located beneath a trolley, other configurations can be employed depending on the embodiment. For example, in alternate embodiments, a carriage sits atop the trolley. In these embodiments, the carriage is aligned with a storage cell when the trolley is located at an elevation at or below the bottom of the buffer position or storage cell in which a material storage item will be placed in or retrieved from. For example, in one embodiment, a towerbot operated material-handler includes a carton handler mounted atop a trolley. In operation, the trolley is positioned adjacent to a storage cell to allow a carriage to move into the storage cell to position a tray including a set of blades into the storage cell from the position atop the trolley. In these embodiments, the carriage is located atop the trolley. Operations to drop off and pickup cartons and / or totes to and from the storage racks for transport to or from a buffer level or equipment located on the material transportation level, respectively, can otherwise occur as described elsewhere herein. According to some embodiments, the carriage is included in a self-propelled satellite bot as described in various embodiments above, but with the satellite bot transported atop the trolley and deployed therefrom.

[0118] Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.

Claims

WHAT IS CLAIMED IS:

1. A storage system comprising: a three-dimensional structure including: an array of cells including: a first plurality of cells configured to retain individual storage containers for retrieval, the array of cells forming a plurality of storage levels located at different elevations within the three dimensional structure, respectively; and a second plurality of cells positioned relative to one another to form a plurality of vertical shafts located within the three dimensional structure, the plurality of vertical shafts configured to permit access to storage cells included in the first plurality of cells at each of the plurality of storage levels; a material transfer level located beneath the plurality of storage levels, the material transfer level including a transportation system configured to move the individual storage containers to locations in the storage system for at least one of receipt of material for storage in an individual storage container and / or removal of material stored from the individual storage container; and a buffer level located above and immediately adjacent the material transfer level; a plurality of towerbots located atop the three dimensional structure, each of the plurality of towerbots including a vertical lift system including a material handler, the plurality of towerbots configured to move the material handler vertically within the plurality of vertical shafts to align the material handler with the first plurality of cells at the different elevations, each of the towerbots configured to move laterally atop the three dimensional structure between multiple different locations atop the three dimensional structure including at least a first position located above a first vertical shaft included in the plurality of vertical shafts and a second position located above a second vertical shaft included in the plurality of vertical shafts; and a plurality of gridbots included in the transportation system, the plurality of gridbots configured to move storage containers on the material transfer level, wherein, with the towerbot located at the first position, the vertical lift system is configured to position the material handler in the first vertical shaft adjacent a first set of storage cells located at a selected elevation included in the different elevations, wherein, with the material handler positioned adjacent the first set of storage cells, the material handler is configured to retrieve a first storage container located at the selectedelevation for a vertical transport from the selected elevation to the buffer level for a release and placement of the first storage container at a first location on the buffer level; wherein the towerbot is configured to move atop the three dimensional structure from the first position to the second position to access the second vertical shaft to retrieve a second storage container with the material handler, the towerbot configured to position the material handler to directly deliver the second storage container to either one of a selected one of the plurality of gridbots or a second location on the buffer level, and wherein the plurality of gridbots are configured to remove the first storage container from the first location after the material handler has released and placed the first storage container at the first location.

2. The storage system of claim 1, wherein the vertical lift system includes a trolley coupled to the material handler during transit within the plurality of vertical shafts, and wherein each of the plurality of towerbots, respectively, includes a winch assembly configured to raise and lower the trolley within the plurality of vertical shafts.

3. The storage system of claim 1, wherein the storage containers include at least one of storage cartons and / or storage bins, wherein the material handlers are configured to secure and move the at least one of storage cartons and / or storage bins, and wherein the plurality of gridbots are configured to move both storage cartons and storage bins.

4. The storage system of claim 3, wherein the plurality of towerbots include a first set of towerbots with material handlers configured to move storage cartons and a second set of towerbots with material handlers configured to move storage bins.

5. The storage system of claim 3, further comprising a plurality of satellite bots configured to operate in a self-powered mode to disengage from a towerbot when operating to retrieve the storage containers from their respective locations within the three-dimensional structure.

6. The storage system of claim 5, wherein the satellite hots each include an energy storage system and a drive system, and wherein the drive system is configured to operate with power supplied from the energy storage system to self-propel the satellite hot from a location beneath the towerbot to a location within a storage cell.

7. The storage system of claim 1, wherein the buffer level includes storage racks, the storage racks each including a set of tines, respectively, and wherein the material handler includes a set of blades spaced relative to one another to fit between adjacent tines included in the set of tines.

8. The storage system of claim 1, wherein each of the plurality of towerbots, respectively, includes a winch assembly configured to raise and lower the material handler within the plurality of vertical shafts.

9. The storage system of claim 1, wherein the array of cells, when viewed from above, form a grid having a width defined by a first quantity of cells arranged in a first row, and a length defined by a second quantity of cells arranged in a second row oriented perpendicular to the first row, and wherein a set of vertical shafts included in the plurality of vertical shafts are arranged adjacent to one another to form a third row that extends across the length of the array of cells or the width of the array of cells, and wherein the set of vertical shafts permit a vertical travel of the material handler from immediately adjacent the towerbot to the material transfer level.

10. The storage system of claim 1, wherein the first plurality of cells includes at least one set of double deep storage cells including the at least one inner cell and an outer cell, wherein a first side of the at least one inner cell is located immediately adjacent a vertical shaft included in the plurality of vertical shafts, the at least one inner cell including a second side located opposite the first side, wherein the outer cell included in the at least one set of double deep storage cells is located adjacent the second side of the at least one inner cell, andwherein, with the material handler positioned adjacent the at least one set of double deep storage cells, the material handler is configured to retrieve a storage container located in the outer cell for the vertical transport to at least one of the material transfer level and / or the buffer level.

11. The storage system of claim 1 , wherein the individual storage containers includes at least one of a rigid storage container and / or a semi-rigid storage container.

12. A container-handling hot configured to move material storage containers within a three-dimensional structure that includes a plurality of storage cells and a plurality of elevator columns, the container-handling hot deployed from a towerbot that travels to the plurality of elevator columns to raise and lower the container-handling bot to different elevations within the three-dimensional structure via the plurality of elevator columns, the container-handling bot comprising: a carriage including an underside; a frame coupled to the carriage, the frame including a tray that is extendable beneath the frame between a collapsed position through a range of extended positions to a fully extended position; an energy storage system included in the carriage; and a drive system that receives power from the energy storage system, the drive system configured to self-propel the container-handling bot from beneath the towerbot into a storage cell located adjacent a selected one of the plurality of elevator columns above which the towerbot is parked, wherein the container-handling bot is configured to move within the storage cell with the frame in the fully extended position, the storage cell including a storage container having a first height, an empty region having a second height greater than the first height formed in a space defined between the underside of the carriage and a top surface of the tray with frame in the fully extended position, and wherein the container-handling bot operates to engage the top surface of the tray with an underside of the storage container by reducing an amount by which the tray is extended beneath the frame once the container-handling bot self-propels itself into the storage cell.

13. The container-handling hot of claim 12, wherein the container-handling hot is configured to travel within a material handler coupled to the towerbot, and wherein the material handler is raised and lowered within the elevator columns via a system including a winch and a cable.

14. The container-handling bot of claim 12, further comprising a vision system configured to capture images of at least one of the storage container and / or contents of the storage container when received within the container-handling bot on the tray.

15. The container-handling bot of claim 12, wherein the tray includes a set of blades each blade included in the set of blades having a top surface, respectively, the respective top surfaces collectively defining the top surface of the tray.

16. The container-handling bot of claim 12, further comprising a set of extenders configured to adjust a position of the tray between the collapsed position through the range of extended positions to the fully extended position;17. The container-handling bot of claim 16, wherein the set of extenders is configured to adjust the space defined between the underside of the carriage and the top surface of the tray to a third height that reduces the space to provide an engagement force that assists in securing the storage container within the container-handling bot for a return to a position beneath the towerbot and vertical transit within the selected one of the plurality of elevator columns.

18. A material handling system, comprising: a storage structure including buffer racks positioned at pre-determined locations within the storage structure; one or more vertical material handling systems configured to vertically transport storage containers to and from the buffer racks; and at least one autonomous mobile robot configured to freely navigate within and external to a structured storage grid, wherein the autonomous mobile robot selectively places one or more storage containers either directly onto the buffer racks or directly onto at least one vertical handlingmodule or at least one mobile robot configured for vertical or horizontal transport within the system.

19. The system of claim 18, wherein the vertical handling module is coupled to a towerbot configured to transport storage containers vertically within the storage structure, and wherein the autonomous mobile robot is configured to directly place one or more storage containers onto the vertical handling module for vertical transport.

20. The system of claim 18, wherein the mobile robot is configured for horizontal transport includes a gridbot, and wherein the autonomous mobile robot is configured to directly place and stack one or more storage containers onto the gridbot at a material transfer level of the storage structure.

21. The system of claim 18, wherein the autonomous mobile robot includes an adjustable lifting mechanism enabling precise vertical positioning of storage containers for accurate placement onto and retrieval from the buffer racks or other robotic systems.

22. The system of claim 18, further comprising a wireless control system configured to coordinate operational states and movements of each of the autonomous mobile robot, the vertical material handling systems, the vertical handling modules, and the autonomous mobile robots, enabling independent and asynchronous exchanges of storage containers.

23. A material storage system, comprising: a vertical storage grid including storage cells and buffer locations; material handling systems each including a trolley having a position- locking system and a storage chamber within which a self-propelled satellite bot is housed; a towerbot configured to raise and lower a selected one of the material handling systems within the vertical storage grid; wherein the satellite bots are configured to autonomously transit from the storage chamber to storage cells and buffer locations to move storage containers with the trolley temporarily secured in a fixed location in the vertical storage grid by the position-locking system.

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