Systems and methods for protecting maintenance or safety zones using mobile robot blockers

Abstract

A mobile robot blocking system includes a pathway blocker for use in a facility with a plurality of pathways configured to allow a plurality of mobile robots to move along the plurality of pathways. The pathway blocker includes: a body; at least one mount disposed on the body; and at least one elongate member configured for installation in the at least one mount, each elongate member being configured for disposition in a corresponding mount. The pathway blocker is configured for disposition at a blocking position in the facility, the at least one elongate member extending into at least one pathway to block mobile robots moving along the at least one pathway when the pathway blocker is at the blocking position, each elongate member being configured to block a corresponding pathway.

Description

[0001] Aty. Docket No. 1127P017370- WO (PCT)

[0002] SYSTEMS AND METHODS FOR PROTECTING MAINTENANCE OR SAFETY ZONES USING MOBILE ROBOT BLOCKERS

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004]

[0001] This application is a non-provisional of and claims the benefit of United States provisional patent application number 63 / 682,721 filed on August 13, 2024, the disclosure of which is incorporated herein by reference in its entirety.

[0005] BACKGROUND

[0006] 1. Field

[0007]

[0002] This invention relates generally to a facility with mobile robots therein, and more particularly, to a maintenance or safety zone at a facility protected by a mobile robot blocker.

[0008] 2. Brief Description of Related Developments

[0009]

[0003] Generally in order fulfillment facilities having automated system for order fulfillment, maintenance personnel access portions of the automated system to perform maintenance procedures. With entry of maintenance personnel into the automated system, all or a part of the automated system is shut down, where operational automation is stopped or leaves the area (i.e., work zone) in which the maintenance personnel are working. To prevent operational automation from entering the work zone, physical barriers may be installed within the automated system structure however, installation of the physical barriers may be time consuming and expensive.

[0010]

[0004] Accordingly, the present disclosure addresses a number of those issues.

[0011] BRIEF DESCRIPTION OF THE DRAWINGS

[0012]

[0005] The foregoing aspects and other features of the present disclosure are explained in the following description, taken in connection with the accompanying drawings, wherein Aty. Docket No. 1127P017370- WO (PCT)

[0013]

[0006] Figs. 1-4 are exemplary schematic illustrations of parts of an order fulfillment facility, utilizing an automated storage and retrieval system, in accordance with the present disclosure;

[0014]

[0007] Fig. 5 is an exemplary partial and simplified overhead schematic illustration of a level of the order fulfillment facility of Figs. 1-4 in accordance with the present disclosure;

[0015]

[0008] Fig. 6 is an exemplary schematic perspective view illustration of a portion of a mobile robot blocking system in accordance with the present disclosure;

[0016]

[0009] Fig. 7 is an exemplary schematic side view illustration of the portion of the mobile robot blocking system of Fig. 6 in accordance with the present disclosure;

[0017]

[0010] Fig. 8 is another exemplary schematic perspective view illustration of the portion of the mobile robot blocking system of Fig. 6 in accordance with the present disclosure;

[0018]

[0011] Fig. 9 is another exemplary schematic side view illustration of the portion of the mobile robot blocking system of Fig. 6 in accordance with the present disclosure;

[0019]

[0012] Fig. 10 is an exemplary schematic perspective view illustration of a portion of a mobile robot blocking system in accordance with the present disclosure;

[0020]

[0013] Fig. 11 is another exemplary schematic perspective view illustration of the portion of the mobile robot blocking system of Fig. 10 in accordance with the present disclosure;

[0021]

[0014] Fig. 12 is an exemplary schematic side view illustration of the portion of the mobile robot blocking system of Fig. 10 in accordance with the present disclosure

[0022]

[0015] Fig. 13 is an exemplary schematic perspective view illustration of an optional feature of the portion of the mobile robot blocking systems of Figs. 6-12 in accordance with the present disclosure;

[0023]

[0016] Figs. 14A and 14B are exemplary schematic illustrations of an optional feature of the portion of the mobile robot blocking systems of Figs. 6-12 in accordance with the present disclosure; Aty. Docket No. 1127P017370- WO (PCT)

[0024]

[0017] Fig. 15 is an exemplary schematic perspective view illustration of an optional feature of the portion of the mobile robot blocking systems of Figs. 6-12 in accordance with the present disclosure;

[0025]

[0018] Figs. 16-19 are exemplary schematic illustrations of a portion of the order fulfillment facility where the portion of the mobile robot blocking system of Figs. 6-12 are positioned to block a mobile robot pathway of the order fulfillment facility in accordance with the present disclosure; and

[0026]

[0019] Fig. 20 is an exemplary flow diagram of a process of blocking mobile robots in a facility in accordance with the present disclosure.

[0027] DETAILED DESCRIPTION

[0028]

[0020] The following detailed description is meant to assist the understanding of one skilled in the art, and is not intended in any way to unduly limit claims connected or related to the present disclosure.

[0029]

[0021] The following detailed description references various figures, where like reference numbers refer to like components and features across various figures, whether specific figures are referenced, or not.

[0030]

[0022] The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the present disclosure. Reference throughout this specification to “one embodiment,” “an embodiment,” “some embodiments”, “an implementation”, “some implementations”, “some applications”, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” “in some embodiments”, “in some implementations”, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. Aty. Docket No. 1127P017370- WO (PCT)

[0031]

[0023] The word “each” as used herein refers to a single object (i.e., the object) in the case of a single object or each object in the case of multiple objects. The words “a,” “an,” and “the” as used herein are inclusive of “at least one” and “one or more” so as not to limit the object being referred to as being in its “singular” form.

[0032]

[0024] Spatial terms such as “left,” “right,” “top,” “bottom,” “upper,” “lower,” “front,” “back,” “vertical,” and “horizontal” as may be used herein are by way of example and illustration only are not meant to limit the description and may be exchanged in position and orientation.

[0033]

[0025] The terms “substantially” and “about” as may be used herein refer to a feature that may be varied within an acceptable manufacturing tolerance for a given application.

[0034]

[0026] Generally speaking, pursuant to present disclosure, systems, apparatuses and methods are provided herein useful to blocking mobile robots, such as from maintenance zones of a facility. In accordance with the present disclosure, a mobile robot blocking system includes a pathway blocker for use in a facility with a plurality of pathways configured to allow a plurality of mobile robots to move along the plurality of pathways. The pathway blocker includes: a body; at least one mount disposed on the body; and at least one elongate member configured for installation in the at least one mount, each elongate member being configured for disposition in a corresponding mount. The pathway blocker may be configured for disposition at a blocking position in the facility, the at least one elongate member extending into at least one pathway to block mobile robots moving along the at least one pathway when the pathway blocker is at the blocking position, each elongate member being configured to block a corresponding pathway.

[0035]

[0027] In accordance with the present disclosure, one or more of the following may be provided: in the system, the pathway blocker may include a storage compartment configured to hold the at least one elongate member, the at least one elongate member being removable from the storage compartment for removable installation in the at least one mount; the pathway blocker may include at least one sensor, each sensor configured to detect secure installation of a corresponding elongate member in a corresponding mount; the at least one elongate member is continuously retained at the at least one mount and is configured to be electrically, hydraulically, or manually extended from a retracted position to an extended position; the at least one elongate member includes at least one telescoped assembly; the at least one mount includes a plurality of mounts Aty. Docket No. 1127P017370- WO (PCT) positioned vertically along the body, the at least one elongate member including a plurality of elongate members configured to extend horizontally from the body to block a group of pathways at different vertical levels; the at least one mount includes at least one mounting bracket, each mounting bracket defining an opening for reception of an elongate member therein; the system further includes at least one indicator on a floor of the facility indicating alignment and positioning of the pathway blocker at the blocking position; the pathway blocker may include a plurality of wheels and at least one locking member configured to limit movement of at least one wheel when the pathway blocker is at the blocking position; the system may include: at least one first coupler of the pathway blocker and at least one second coupler at a floor of the facility, wherein each first coupler is configured to engage a corresponding second coupler to limit movement of the pathway blocker at the blocking position; and the at least one first coupler comprises a pin and the at least one second coupler comprises a cavity in the floor of the facility, the pin configured to extend from the pathway blocker for reception in the cavity.

[0036]

[0028] In accordance with the present disclosure, there is provided a method of blocking mobile robots at facilities, the method including: disposing a pathway blocker at a blocking position in a facility having a plurality of pathways along which a plurality of mobile robots move, wherein the pathway blocker comprises a body, at least one mount disposed on the body, and at least one elongate member configured for installation in the at least one mount, each elongate member being configured for disposition in a corresponding mount; and causing a respective elongate member from the pathway blocker to extend into at least one pathway to block mobile robots moving along the at least one pathway.

[0037]

[0029] In accordance with the present disclosure, the method may include one or more of the following: the pathway blocker may include a storage compartment configured to hold the at least one elongate member, the at least one elongate member being removable from the storage compartment for removable installation in the at least one mount; by at least one sensor of the pathway blocker, detecting secure installation of a corresponding elongate member in a corresponding mount; the at least one elongate member is continuously retained at the at least one mount, and the method includes electrically, hydraulically, or manually extending the at least one elongate member from a retracted position to an extended position; the at least one mount includes a plurality of mounts positioned vertically along the body, the at least one elongate member Aty. Docket No. 1127P017370- WO (PCT) including a plurality of elongate members configured to extend horizontally from the body to block a group of pathways at different vertical levels; the at least one mount includes at least one mounting bracket, each mounting bracket defining an opening for reception of an elongate member therein; by at least one indicator on a floor of the facility, indicating alignment and positioning of the pathway blocker at the blocking position; the pathway blocker may include a plurality of wheels and at least one locking member, and the method may include by the at least one locking member, limiting movement of at least one wheel when the pathway blocker is at the blocking position; and the pathway blocker may include at least one first coupler of the pathway blocker and wherein at least one second coupler is disposed at a floor of the facility, the method may include by each first coupler, engaging a corresponding second coupler to limit movement of the pathway blocker at the blocking position.

[0038]

[0030] Without limitation, the present disclosure is directed generally to a facility, such as an order fulfillment facility, that includes multiple mobile robots (or bots) that operate to pick and transfer containers in the context of an automated storage and retrieval system. The mobile robots may move about the facility and retrieve containers, or totes, of goods that are stored in specific storage locations in the facility, as part of the automated storage and retrieval system. Occasionally, certain areas or zones of the facility may require maintenance, such as, for example, removing or repairing a damaged or non-functioning mobile robot in a certain area or zone (although other types of maintenance and servicing are also contemplated). When this situation occurs, it may require some or all of the facility to shut down while the maintenance is performed so as to prevent mobile robots from entering the area or zone and undesired interaction between the mobile robots and a maintenance individual.

[0039]

[0031] Without limitation, it may be desirable to minimize the number of partial or complete system stops that are required in case of maintenance required in a particular area or zone of the facility. Some scenarios of mishaps may require an individual, such as a technician, to physically enter a portion of the system to perform the maintenance. In this instance, the system and / or facility may be shut down partially or completely to prevent undesired interaction between automated portions of the system and / or facility and the individual. Aty. Docket No. 1127P017370- WO (PCT)

[0040]

[0032] Without limitation, the present disclosure addresses the issue where the system has to be shut down when a person / individual needs to enter to service the system. The present disclosure allows zones within the system to be fenced / blocked off, which allows the remainder of the system to continue running during service. In order to create zoning for maintenance within the system and undesired interaction between automation system components and a technician, a down aisle “blocker” (also referred to herein as a mobile bot-blocking cart) may be used to stop stray bots from interfacing with a technician. A down aisle blocker is intended to stop a stray bot from entering the space where a user may be performing maintenance within the system. This mobile bot-blocking cart may be deployed to substantially prevent a bot from entering a designated zone in the system. The present disclosure generally involves the use of a mobile cart with elongate members (such as tubes) to physically block a mobile robot from entering a zone. The mobile cart may use electrical or hydraulic actuators to extend the elongate members for blocking a zone. Other examples of bot blocking systems are disclosed in U.S. Publication No. 2022 / 0281494, published September 8, 2022, entitled “Mechanical Guard Bot Blocking System,” and International Publication No. WO 2024 / 076682, published April 11, 2024, entitled “Bot Blocking System,” which are incorporated herein by reference in their entirety.

[0041]

[0033] Figs. 1-4 show parts of an order fulfillment facility 100 (or storage facility) that utilizes an automated storage and retrieval system (ASRS). More specifically, as part of the ASRS, Figs. 1 and 2 show a storage structure 102 that is generally intended to store various items at a number of storage locations 104. The storage structure 102 may include a y-z array of storage locations 104 in horizontal rows and level changing towers 105 (or vertical towers or climbing channels) along the rows. Mobile robots may travel between storage levels in the z-direction within the level changing towers. Rows of storage locations 104 may be arranged to face each other, separated by horizontal pathways or aisles 106.

[0042]

[0034] The storage structure 102 may include decks 108 (or transit planes or areas) spaced apart at different horizontal levels of the storage structure 102. The decks 108 may extend between the aisles 106 so that mobile robots can maneuver in the x-y plane of each deck 108 to travel between different aisles 106. Further details relating to the general structure and operation of embodiments of storage structures and mobile robots, such as may be used in conjunction with this disclosure, are disclosed in U.S. Patent No. 9,139,363, issued September 22, 2015, entitled “Automated Aty. Docket No. 1127P017370- WO (PCT)

[0043] System for Transporting Payloads”; U.S. Patent No. 10,040,632, issued August 7, 2018, entitled” Automated System for Transporting Payloads”; U.S. Patent 10,435,241, issued October 8, 2019, entitled “Storage and Retrieval System”; U.S. Patent No. 10,952,533, issued March 23, 2021, entitled “Modular Structure for an Automated Storage and Retrieval System”; and U.S. Patent No. 11,142,398, issued October 12, 2021, entitled “Order Fulfillment System”; which patents are all incorporated by reference herein in their entirety.

[0044]

[0035] Figs. 3 and 4 show workstations, or container processing stations 110, at the facility 100. Operators (human individuals and / or robotic operators) work at the container processing stations 110 and may transfer goods / items / eaches to containers. Various operations may be performed at the container processing stations 110. Human or robotic operators, or pickers, may receive containers of eaches for transfer of the eaches into order containers. Mobile robots may perform transport operations, including moving containers of eaches between storage locations 104 and the workstations 110 and including transporting order containers away from the workstations. Examples of workstations 110 and picking and transfer operations, such as may be used in conjunction with this disclosure, are disclosed, for example, in U.S. Patent No. 11,845,610, issued December 19, 2023, entitled “Automated Decant System”; U.S. Patent Publication No. 2021 / 0380343, published December 9, 2021, entitled “Robotic Each Picking in a MicroFulfillment Center”; and U.S. Patent No. 10,984,375, issued April 20, 2021, entitled “Picking Workstation with Mobile robots and Machine Vision Verification of Each Transfers Performed by Human Operators,” all of which are incorporated by reference herein in their entirety.

[0045]

[0036] Fig. 5 shows a partial and simplified overhead view of a level 115 in the storage structure 102. This overhead view shows aisles 106 with storage locations 104 to either side of the aisle 106. It further shows mobile robot 128 that is configured (e.g., with any suitable drive system) to traverse the aisles 106 and access the storage locations 104. The mobile robot 128 can also travel along decks 108 to allow it to turn and to allow it to exit one aisle 106 and enter a different one.

[0046]

[0037] As described above, the present disclosure may provide for a storage structure 102 with aisles / pathways 106 and decks 108, and with mobile robots configured to move along the pathways 106 and decks 108 in the storage structure 102. The storage structure 102 may be part of an order fulfillment facility 100 that includes storage locations 104 for storing containers containing Aty. Docket No. 1127P017370- WO (PCT) goods / items / eaches, with the storage locations 104 being accessible to mobile robots by a horizontal pathway 106. The term “each” generally refers to an individual unit of a product or merchandise item. The mobile robots may be configured (e.g., with any suitable transfer mechanism) to access the storage locations 104 to deposit or retrieve containers at the storage locations 104.

[0047]

[0038] Figs. 6-9 show an example of a mobile robot blocking system 200 with a pathway blocker 202. As addressed further below, it is generally contemplated that the pathway blocker 202 may be disposed next to horizontal pathways 106 along which mobile robots are traveling. These horizontal pathways 106 may be generally arranged, or stacked, vertically to provide multiple levels of horizontal pathways 106 along which the mobile robots may move. It is desirable to be able to block each of the different levels of travel. The pathway blocker 202 may include multiple elongate members 204 that extend to block the multiple levels of horizontal pathways 106.

[0048]

[0039] Fig. 6 shows a perspective view of the pathway blocker 202 in which one or more elongate members 204 are removably mounted on the pathway blocker 202, and Fig. 7 shows a side view of the pathway blocker 202. The pathway blocker may include a body 206 with at least one mount 208 disposed on the body 206. At least one elongate member 204 may be configured for installation in the at least one mount 208 with each elongate member 204 being configured for disposition in a corresponding mount 208.

[0049]

[0040] There may be mounts 208 that support six elongate members 204, although, as is evident, the pathway blocker 202 may be designed to mount a different number (e.g., more or less than six) of elongate members 204. There may be two mounts 208 supporting each elongate member 204, although a different number (e.g., more or less than two) of mounts 208 may be used. As addressed further below, the pathway blocker 202 may be configured for disposition at a blocking position in the facility 100 in which the elongate member(s) 204 extend into pathway (s) 106 to block mobile robots moving along the pathway(s) 106 when the pathway blocker 202 is at the blocking position. Each elongate member 204 is configured to block a corresponding pathway 106. Where there are six elongate members 204, the six mounted elongate members 204 may block six different pathways 106 along which mobile robots travel (e.g., the number of elongate members may block a corresponding number of different pathways). Aty. Docket No. 1127P017370- WO (PCT)

[0050]

[0041] The elongate members 204 may be in the form of posts, rods, or tubes, or have any other configuration / form so as to block a pathway. The posts, rods, or tubes may be designed such that they may be discarded after an impact by a mobile robot, if the posts, rods, or tubes are damaged. It may be more desirable to suffer damage to a relatively low-cost post, rod, or tube, than to the mobile robot or to the structure of the system.

[0051]

[0042] The elongate members 204, or blockers, may be in the form of carbon steel tubes, although the elongate members 204 may be formed of any suitable material and have any suitable cross- sectional shape. It has been found that elongate members 204 of this material may deflect little enough under the force of a mobile robot impact to so as to not allowing the mobile robot to travel more than a predetermined distance into the space being blocked, such as in accordance with any suitable industry standards. The predetermined distance may be about six inches (or about 15 cm). Other materials, such as, for example, polycarbonate tubes, might also be suitable and provide certain advantages. The polycarbonate would be strong (although not as strong as carbon steel), but it would also be much lighter than the steel. It would also deflect more, which may allow the pathway blocker 202 to possibly block a mobile robot without damaging the mobile robot beyond repair.

[0052]

[0043] The body 206 may include a base portion 210 attached to wheels 212 to make the pathway blocker 202 mobile. It is generally contemplated that, when not in use, the pathway blocker 202 may be stored in a designated storage area and / or in some low traffic portion of the facility 100. Then, when there is a need for maintenance and the establishment of a blocking zone, the pathway blocker 202 may be moved from the storage area to the blocking position. At that time, the elongate member(s) 204 may then be mounted to place the pathway blocker 202 in an operational condition. The pathway blocker 202 may be positioned upstream of a designated safety or maintenance zone so as to substantially protect this downstream zone from mobile robots.

[0053]

[0044] The pathway blocker 202 may include a storage compartment 214 that holds the elongate member(s) 204 when not in use. The elongate member(s) 204 are removable from the storage compartment 214 for removable installation in the mount(s) 208. In Figs. 2 and 3, six elongate member(s) 204 have been mounted, and storage compartment 214 is holding additional or replacement elongate member(s) 204. Figs. 8 and 9 show the storage compartment 214 with all Aty. Docket No. 1127P017370- WO (PCT) elongate member(s) 204 removed, i.e., empty, and with five elongate member(s) 204 being mounted in the six positions, i.e., the second from top position is unoccupied. It is contemplated that that the material, weight, and location of the storage compartment 214 are selected so as to provide stability to the pathway blocker 202, especially when one or more of the elongate member(s) 204 may be impacted by moving mobile robots.

[0054]

[0045] The pathway blocker 202 may include one or more vertical posts 216 that include the mount(s) 208. The mount(s) 208 may be spaced at predetermined vertical intervals along the post(s) 216. The mount(s) 208 may be positioned vertically along the body 206 with the elongate member(s) 204 configured to extend horizontally from the body 206 to block a group of pathways 106 at different vertical levels. As can be seen, the mount(s) 208 may be in the form of mounting brackets with each mounting bracket defining an opening 218 for reception of an elongate member 204 therein. The pathway blocker 202 may include one or more angled supports 219 connecting the base portion 210 to a post 216.

[0055]

[0046] Figs. 10-12 show a mobile robot blocking system 300 with a pathway blocker 302. Again, it is generally contemplated that the pathway blocker 302 will be disposed next to horizontal pathways 106 along which mobile robots are traveling. However, with respect to Figs. 10-12, it is contemplated that the elongate members 304 are more permanently mounted on the pathway blocker 302 and are not generally intended for removal when not in use.

[0056]

[0047] Figs. 10 and 11 show perspective views of the pathway blocker 302 in which one or more elongate members 304 are generally in an extended position, and Fig. 12 shows a side view of the pathway blocker 302. The pathway blocker 302 may include a body 306 with mount(s) 308 disposed on the body 306. The mount(s) 308 may be in the form of sleeves that each hold and support an elongate member 304. The elongate member(s) 304 are continuously retained at the mount(s) 308 and are configured to be electrically, hydraulically, or manually extended (e.g., with any suitable electrical, hydraulic, or manual actuator) from a retracted position to an extended position. When not in use, the elongated member(s) 304 may be retracted into the mount(s) 308, such as when the pathway blocker 302 is stored. When in use, the elongated member(s) 304 may be extended from the mount(s) 308 into the horizontal pathways 106. One or more of the elongate Aty. Docket No. 1127P017370- WO (PCT) members 304 may form a telescoped assembly, such as in combination with its corresponding mount 308.

[0057]

[0048] Like the pathway blocker 202, the pathway blocker 302 is configured for disposition at a blocking position in the facility 100. In this blocking position, the elongate member(s) 304 are extended into pathway(s) to block mobile robots moving along the pathway(s) when the pathway blocker 302 is at a blocking position in the facility 100. Each elongate member 304 is configured to block a corresponding pathway. The pathway blocker 302 may have fixed mount(s) 308 with electrical or hydraulic actuators to extend the elongate member(s) 304 (such as tubes) for blocking a zone. The pathway blocker 302 may have fixed mount(s) 308 supporting elongate member(s) 304 that may be manually moved (or pulled out) by an individual to an extended position. A combination of electrical or hydraulic actuators and manually actuated elongate member(s) 304 may be provided.

[0058]

[0049] The body 306 may include a base portion 310 attached to wheels 312. When not in use, the pathway blocker 302 may be stored in a designated storage area and / or in some low traffic portion of the facility 100. Then, when its use is required, the pathway blocker 302 may be moved from the storage area to the blocking position. At that time, the elongate member(s) 304 may be extended to place the pathway blocker 302 in an operational condition to block the pathway (s) with the elongate member(s) 304.

[0059]

[0050] Like the pathway blocker 202, the pathway blocker 302 may include one or more vertical posts 316 that support the mount(s) 308. The mount(s) 308 may be spaced at predetermined vertical intervals along the post(s) 316. The mount(s) 308 may be positioned vertically so that the elongate member(s) 304 are configured to be extended horizontally from the body 306 to block a group of pathways 106 at different vertical levels.

[0060]

[0051] Figs. 13-15 show additional optional features that may be used with one or both of the pathway blockers 202, 302 (or with other forms of the pathway blockers within the scope of the present disclosure). Fig. 13 is a partial view that shows the wheels 212, 312, which may be in the form of caster wheels. It is generally contemplated that the pathway blocker 202, 302 may include wheels 212, 312 with at least one locking member 220 configured to limit movement of at least one wheel 212, 312 when the pathway blocker 202, 302 is at the blocking position. Aty. Docket No. 1127P017370- WO (PCT)

[0061]

[0052] Figs. 14A and 14B show another feature limiting the movement of the pathway blocker 202, 302 when in a blocking position. More specifically, the system 200 may include a first coupler 222 at the pathway blocker 202, 302 and a second coupler 112 at the floor 114 of the facility 100. The first coupler 222 is configured to engage the second coupler 112 to limit movement of the pathway blocker 202, 302 at the blocking position. The first coupler 222 may be in the form of a pin and the second coupler 112 may be in the form of a cavity in the floor 114 of the facility 100 such that the pin is configured to extend from the pathway blocker 202, 302 for reception in the cavity (or hole in the floor 114). The pin may be bolted or otherwise fastened so as to extend into the cavity.

[0062]

[0053] When not at the blocking position, the pin may be in a retracted position so as not to engage the floor 114 of the facility 100. When at the blocking position, and when aligned with the cavity, the pin may be shifted to an engagement position in which it extends into the cavity. This insertion of one or more pins may also indicate proper alignment and orientation of the pathway blocker 202, 302 at the blocking position, i.e., confirmation of positioning. It is also contemplated that a sensor 116 may be disposed at the floor 114 of the facility near or adjacent the cavity. The sensor 116 may be arranged and configured so that the sensor 116 detects when the sensor 116 engages a portion of the pin to indicate that the pin is securely disposed in the cavity.

[0063]

[0054] There may be multiple sets of pins / cavities and multiple sensors 116 associated with each pathway blocker 202, 302, such as, for example, at the front, back, and / or sides of pathway blocker 202, 302. The sensors 116 may indicate when the pathway blocker 202, 302 is in position and secured such that an individual may enter the maintenance or safety zone (such as by illuminating a sensor light). It is generally contemplated that this feature may be used with one or both of the pathway blockers 202, 302 and with additional forms of the pathway blocker that are within the scope of the present disclosure. This coupling feature (e.g., pin / cavity) may be used in addition to, or as an alternative to, the wheel locking feature of Fig. 13.

[0064]

[0055] In accordance with the present disclosure, it is contemplated that the system 200, 300 may include indicator(s) 118 on the floor 114 indicating alignment and positioning of the pathway blocker 202, 302 at the blocking position. These indicators 118 may be in the form of painted Aty. Docket No. 1127P017370- WO (PCT) symbols, fiducial markers, or other markings. The cavity (which may be covered with a cap when not in use) may serve as that indicator 118.

[0065]

[0056] Fig. 15 shows an optional feature that is generally contemplated for use with pathway blocker 202. Tt is contemplated that the pathway blocker 202 may include one or more sensors 224 associated with the mounts 208 (such as integrated safety sensors). Each of these sensors 224 may be configured to detect secure installation of a corresponding elongate member 204 in a corresponding mount 208. For example, each sensor 224 may indicate that an elongate member 204 is securely positioned and locked within a mount 208, such as, for instance, by illuminating a sensor light adjacent the mount 208. Illumination of all of the sensor lights may indicate that all elongate members 204 are in place and that the pathway blocker 202 is properly engaged. One indicator (such as one sensor light) may be used to indicate that all elongate members 204 are securely mounted. This indication may be required before personnel enter the maintenance or safety zone. The sensor 224 may be provided for pathway blocker 302 to provide an indication that all elongate members 304 are in place and that the pathway blocker 302 is properly engaged (see Fig. 11).

[0066]

[0057] Figs. 16-19 show a pathway blocker 202 as it is moved into a blocking position next to horizontal pathways 106 being traversed by mobile robots (it is noted pathway blocker 202 is illustrated for exemplary purposes only and that pathway blocker 302 may be moved and positioned next to horizontal pathways 106 being traversed by mobile robots in the same or similar manner as that described with respect to pathway blocker 202). Fig. 16 shows an overhead view where the pathway blocker 202 is in a first position approaching the blocking position and is then in a second position (the blocking position) in which the length of the body 206 is generally parallel to the direction of travel of the mobile robots along the horizontal pathways 106. The blocking position may be between two workstations 110 but without obstructing workstation operations. Blocking positions may be next to horizontal pathways 106 and between workstations 110 so as not to obstruct access or movement to the workstations 110. Once at the blocking position, the pathway blocker 202 may be locked into place, such as, for example, with locking wheels and / or coupling elements described above. In Figs. 16 and 17, the elongate members 204 are in the storage compartment 214 and have not yet been installed. Aty. Docket No. 1127P017370- WO (PCT)

[0067]

[0058] Figs. 18 and 19 show perspective views of the pathway blocker 202 in the blocking position. Like Figs. 16 and 17, in the blocking position, the length of the body 206 is generally parallel to the horizontal pathways 106, and the blocking position is between two workstations 110. However, unlike Figs. 16 and 17, the elongate members 204 have been installed in the mounts 208, although some elongate members 204 also remain in the storage compartment 214. Accordingly, with the elongate members 204 extending into the horizontal pathways 106, the pathway blocker 202 is in an operational condition.

[0068]

[0059] Fig. 20 shows a process 400 of blocking mobile robots at facilities. It is generally contemplated that facility has multiple pathways along which mobile robots move, and in one form, it may be desirable to block access to a zone where an individual is performing maintenance or is otherwise present. It is generally contemplated that the process 400 uses a form of pathway blocker, such as described above. The process 400 may use some or all of the components described above, such as, for example components of the pathway blockers described above.

[0069]

[0060] At block 402, a pathway blocker 202, 302 is moved to a blocking position. For example, the pathway blocker 202, 302 may be a pathway blocker described above, or a modified version of the pathway blocker 202, 302. It is generally contemplated that the pathway blocker 202, 302 may be used at a facility 100 (such as an order fulfillment facility using an automated storage and retrieval system) having a plurality of pathways along which mobile robots move. The pathway blocker 202, 302 may be kept in a storage location or area when not in use. There may be designated blocking positions at the facility 100 that may be indicated in some manner, including but not limited to, for example, positions upstream of or near to workstations 110. It is contemplated that the pathway blocker 202, 302 may be permanently or semi-permanently stationed at a blocking position.

[0070]

[0061] At block 404, optionally, wheels 212, 312 of the pathway blocker 202, 302 may be locked at the blocking position. It is generally contemplated that the pathway blocker 202, 302 may be stationary at the blocking position and may be ready to receive the impact of one or more mobile robots with limited movement of the pathway blocker 202, 302. The pathway blocker may include components, such as, for example, a weighted body or storage compartment, to provide the Aty. Docket No. 1127P017370- WO (PCT) pathway blocker with extra stability. In this regard, the speed and weight of the mobile robots may be considered.

[0071]

[0062] At block 406, optionally, a coupling element (such as described with respect to Figs. 14A and 14B) on the pathway blocker 202, 302 is engaged with a coupling element on the floor 114 of the facility 100. This feature is another optional feature that seeks to place the pathway blocker 202, 302 in a stationary blocking position and ready to receive the impact of one or more mobile robots (which may be as an alternative or in addition to the locking wheels and weighted components addressed above). The coupling element on the pathway blocker 202, 302 may include the pin and the coupling element at the floor may include the cavity in the floor 114 of the facility 100 that can receive the pin in the manner described above with respect to Figs. 14A and 14B. This cavity may be covered with a cap when not in use and may also serve to act as an indicator of the blocking position and the alignment of the pathway blocker 202, 302 at the blocking position. It is generally contemplated that multiple sets of coupling elements may be used for each pathway blocker 202, 302.

[0072]

[0063] At block 408, optionally, a sensor 116 detects the engagement of the coupling elements. It is contemplated that the sensor 116 is near to or adjacent to the coupling element in the floor 114 of the facility 100. The sensor 116 may be configured so as to determine its engagement with the coupling element on the pathway blocker 202, 302, and when properly engaged, it may indicate that the pathway blocker 202, 302 is properly positioned at the blocking position. This indication may be required before personnel enter the maintenance or safety zone. Multiple sensors 116 may be used for each pathway blocker 202, 302 with each sensor 116 corresponding to one of the coupling elements at the floor 114.

[0073]

[0064] At block 410, optionally, elongate member(s) 204 are installed into mount(s) 208 on the pathway blocker 202. For example, the pathway blocker may be some form of pathway blocker 202, such as described above, which generally contemplates the installation of elongate members 204 into mounts 208 at the blocking position. These elongate members 204 may be in the form of posts, rods, or tubes that, when installed in the vertically-spaced mounts 208, may extend horizontally from the body 206 to block a group of pathways at different vertical levels. Aty. Docket No. 1127P017370- WO (PCT)

[0074]

[0065] At block 412, optionally, the sensor 224 detects the installation of the elongate member(s) 204 into the mount(s) 208. This step, like block 410, contemplates the use of some form of pathway blocker involving the installation of elongate members 204 into mounts 208 on the pathway blocker 202. The sensor 224 may be configured so as to determine receipt of an elongate member 204 at a mount 208 (such as, for example, receipt within an opening of a mounting bracket). When an elongate member 204 is properly installed, it may indicate that the pathway blocker 202 is properly positioned at the blocking position. This indication may be required before personnel enter the maintenance or safety zone. Multiple sensors 224 may be used for each pathway blocker with each sensor 224 corresponding to one of the mounts 208.

[0075]

[0066] At block 414, optionally, elongate member(s) 304 are electrically, hydraulically, or manually extended from retracted positions in the mount(s) 308. For example, the pathway blocker may be some form of pathway blocker 302 that generally contemplates that the elongate members 304 may be permanently or semi-permanently held in the mounts 308. The mounts 308 may be vertically spaced along the pathway blocker 302. When not in use, each elongate member 304 may be held in a retracted position in its mount 308, and when in use, each elongate member 304 may be extended horizontally from the body 306 to block a group of pathways at different vertical levels. Although the elongate members 304 may be permanently or semi-permanently held in the mounts 308, it is also contemplated that retractable and extendable elongate members may be temporarily held in the mounts and installed for use when the pathway blocker 302 is at the blocking position.

[0076]

[0067] At block 416, elongate member(s) 204, 304 are caused to extend into pathways to block mobile robots. This extension of the elongate member(s) 204, 304 into pathways may be caused by installing elongate members 204 that are stored in a storage compartment into mounts 208, such as, for example, using pathway blocker 202; or this extension into pathways may be caused by extending elongate members 304 from retracted positions in the mounts 308, such as, for example, using pathway blocker 302.

[0077]

[0068] An example of the context and implementation of the process 400 is as follows. Initially, an event may occur at the facility 100 requiring individual maintenance and / or intervention, and mobile robots may be routed away from the impacted zone or area. It is determined that a pathway Aty. Docket No. 1127P017370- WO (PCT) blocker 202, 302 is warranted to help set up a maintenance or safety zone for an individual to enter. The pathway blocker 202, 302 is moved and aligned with the horizontal pathway structure, and the pathway blocker 202, 302 is then locked into the blocking position (such as with the use of locking castor wheels and / or pins or other coupling elements as described herein). Sensors (as described herein) may indicate that the pathway blocker 202, 302 is secured at the blocking position.

[0078]

[0069] Next, blocking may be engaged manually (such as with the manual installation and / or extension of elongate members 204) or automatically (such as with the use of electrical or hydraulic actuators to cause the extension of elongate members 304). Sensors 224 may indicate that the elongate members 204, 304 are properly secured in their mounts and / or that they have been properly extended. The system may then indicate that it is safe for the individual / technician to enter the maintenance or safety zone.

[0079]

[0070] The technician may enter the maintenance or safety zone and may perform the required maintenance or repair. When the work is completed, the technician exits the maintenance or safety zone and indicates in some manner that he or she has left the zone. The technician or the system may then disengage the blocking, and the system may return to normal functionality. Mobile robots may resume travel through the former maintenance / safety zone, and the pathway blocker may be returned to a storage area or location.

[0080]

[0071] It should be understood that the foregoing description is only illustrative of the present disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the present disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications and variances that fall within the scope of any claims appended hereto. Further, the mere fact that different features are recited in mutually different dependent or independent claims does not indicate that a combination of these features cannot be advantageously used, such a combination remaining within the scope of the present disclosure.

[0081]

[0072] What is claimed is:

Claims

Aty. Docket No. 1127P017370- WO (PCT)CLAIMS1. A mobile robot blocking system comprising: a pathway blocker for use in a facility with a plurality of pathways configured to allow a plurality of mobile robots to move along the plurality of pathways, the pathway blocker comprising: a body; at least one mount disposed on the body; and at least one elongate member configured for installation in the at least one mount, each elongate member being configured for disposition in a corresponding mount; wherein the pathway blocker is configured for disposition at a blocking position in the facility, the at least one elongate member extending into at least one pathway to block mobile robots moving along the at least one pathway when the pathway blocker is at the blocking position, each elongate member being configured to block a corresponding pathway.

2. The mobile robot blocking system of claim 1 , wherein the pathway blocker further comprises a storage compartment configured to hold the at least one elongate member, the at least one elongate member being removable from the storage compartment for removable installation in the at least one mount.

3. The mobile robot blocking system of claim 1, wherein the pathway blocker further comprises at least one sensor, each sensor configured to detect secure installation of a corresponding elongate member in a corresponding mount.

4. The mobile robot blocking system of claim 1, wherein the at least one elongate member is continuously retained at the at least one mount and is configured to be electrically, hydraulically, or manually extended from a retracted position to an extended position.

5. The mobile robot blocking system of claim 4, wherein the at least one elongate member comprises at least one telescoped assembly.Aty. Docket No. 1127P017370- WO (PCT)6. The mobile robot blocking system of claim 1, wherein the at least one mount comprises a plurality of mounts positioned vertically along the body, the at least one elongate member comprising a plurality of elongate members configured to extend horizontally from the body to block a group of pathways at different vertical levels.

7. The mobile robot blocking system of claim 1, wherein the at least one mount comprises at least one mounting bracket, each mounting bracket defining an opening for reception of an elongate member therein.

8. The mobile robot blocking system of claim 1, further comprising at least one indicator on a floor of the facility indicating alignment and positioning of the pathway blocker at the blocking position.

9. The mobile robot blocking system of claim 1, wherein the pathway blocker further comprises a plurality of wheels and at least one locking member configured to limit movement of at least one wheel when the pathway blocker is at the blocking position.

10. The mobile robot blocking system of claim 1, further comprising: at least one first coupler of the pathway blocker; and at least one second coupler at a floor of the facility; wherein each first coupler is configured to engage a corresponding second coupler to limit movement of the pathway blocker at the blocking position.

11. The mobile robot blocking system of claim 10, wherein the at least one first coupler comprises a pin and the at least one second coupler comprises a cavity in the floor of the facility, the pin configured to extend from the pathway blocker for reception in the cavity.

12. A method of blocking mobile robots at facilities, the method comprising: disposing a pathway blocker at a blocking position in a facility having a plurality of pathways along which a plurality of mobile robots move, wherein the pathway blocker comprises a body, at least one mount disposed on the body, and at least one elongate member configured for installationAty. Docket No. 1127P017370- WO (PCT) in the at least one mount, each elongate member being configured for disposition in a corresponding mount; and causing a respective elongate member from the pathway blocker to extend into at least one pathway to block mobile robots moving along the at least one pathway.

13. The method of claim 12, wherein the pathway blocker further comprises a storage compartment configured to hold the at least one elongate member, the at least one elongate member being removable from the storage compartment for removable installation in the at least one mount.

14. The method of claim 12, further comprising: by at least one sensor of the pathway blocker, detecting secure installation of a corresponding elongate member in a corresponding mount.

15. The method of claim 12, wherein the at least one elongate member is continuously retained at the at least one mount, the method further comprising: electrically, hydraulically, or manually extending the at least one elongate member from a retracted position to an extended position.

16. The method of claim 12, wherein the at least one mount comprises a plurality of mounts positioned vertically along the body, the at least one elongate member comprising a plurality of elongate members configured to extend horizontally from the body to block a group of pathways at different vertical levels.

17. The method of claim 12, wherein the at least one mount comprises at least one mounting bracket, each mounting bracket defining an opening for reception of an elongate member therein.

18. The method of claim 12, further comprising: by at least one indicator on a floor of the facility, indicating alignment and positioning of the pathway blocker at the blocking position.Aty. Docket No. 1127P017370- WO (PCT)19. The method of claim 12, wherein the pathway blocker further comprises a plurality of wheels and at least one locking member, the method further comprising: by the at least one locking member, limiting movement of at least one wheel when the pathway blocker is at the blocking position.

20. The method of claim 12, wherein the pathway blocker comprises at least one first coupler of the pathway blocker and wherein at least one second coupler is disposed at a floor of the facility, the method further comprising: by each first coupler, engaging a corresponding second coupler to limit movement of the pathway blocker at the blocking position.

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