Automated storage and retrieval system and methods

Patent metadata

Field	Value
Publication number	US-10759601-B2
Application number	US-201916557100-A
Country	US
Kind code	B2
Filing date	Aug 30, 2019
Priority date	Feb 24, 2017
Publication date	Sep 1, 2020
Grant date	Sep 1, 2020

Abstract

A method for operating an automated storage and retrieval system includes transferring a first item storage container from an aisle to a first region of a first storage location, positioning a second item storage container in the aisle proximate the first item storage container, interlocking the second item storage container to the first item storage container by engaging a releasable coupling structure extending there between, and applying, in a first direction transverse to the aisle, a force to the second item storage container sufficient in magnitude and duration to cause the first item storage container to occupy the second region of the first storage location and the second item storage container to occupy the first region of the first storage location, whereby the first and second item storage containers remain interlocked while in the first storage location.

First claim

What is claimed is:

1. A material handling system for storing or retrieving a plurality of Items, comprising:
a first rack of storage locations;
a second rack of storage locations spaced apart from the first rack forming a first aisle between the first and second racks;
a third rack of storage locations spaced apart from the second rack forming a second aisle between the second and third racks;
a first vehicle operable within the first aisle to deliver items to and retrieve items from the storage locations in the first and second storage racks;
a second vehicle operable within the second aisle to deliver items to and retrieve items from the storage locations in the second and third racks;
wherein the second rack is configured so that an item delivered to the second rack by the second vehicle can be retrieved from the second rack by the first vehicle;
wherein the storage locations of the first, second or third storage rack are configured to accommodate a plurality of storage containers; and
wherein each of the storage containers comprise one or more releasable connector configured so that two storage containers can be connected to one another when the two storage containers are stored within one of the storage locations.

2. The material handling system of claim 1 comprising:
a first track positioned adjacent a first side of the first rack;
a second track positioned adjacent a first side of the second rack, wherein the first and second tracks guide the first vehicle in the first aisle;
a third track positioned adjacent a second side of the second rack; and
a fourth track positioned adjacent a first side of the third rack, wherein the third and fourth tracks guide the second vehicle in the second aisle.

3. The material handling system of claim 2 wherein each of the first, second third and fourth tracks comprise a plurality of vertical track sections interconnected by a plurality of horizontal track sections.

4. The material handling system of claim 1 wherein each of the first, second and third racks comprise an array of storage locations.

5. The material handling system of claim 1 wherein the first vehicle comprises a first transfer mechanism configured to transfer items into the storage locations in the second rack and the second vehicle comprises a second transfer mechanism configured to transfer items from the storage locations in the second rack onto the second vehicle.

6. The material handling system of claim 1 comprising:
a first picking station positioned along the first aisle wherein the first aisle is configured so that the first vehicle is able to retrieve items from the first or second racks and deliver the items to the first picking station; and
a second picking station positioned along the second aisle wherein the second aisle is configured so that the second vehicle is able to retrieve items from the second or third racks and deliver the items to the second picking station,
wherein the second rack is configured so that items transferred to the second rack from the vehicle in the second aisle may be retrieved by the first vehicle in the first aisle and delivered to the first picking station so that items from the second aisle can be transferred to the first aisle and delivered to the first picking station.

7. The material handling system of claim 1 wherein the first and second vehicle are independently operable self-propelled vehicles.

8. The material handling system of claim 1 wherein the first vehicle is constrained to movement within the first aisle and the second vehicle is constrained to movement within the second aisle.

9. The material handling system of claim 1 wherein the first rack comprises a first array of bins disposed in a plurality of rows or columns, the second rack comprises a second array of bins disposed in a plurality of rows or columns, and the third rack comprises a third array of bins disposed in a plurality of rows or columns.

10. A method for operating an automated storage and retrieval system, comprising the steps of:
conveying a first vehicle through a first aisle between a first rack of storage locations and a second rack of storage locations;
conveying a second vehicle through a second aisle between the second rack of storage locations and a third rack of storage locations;
transferring an item from one of the storage locations on the first rack to the first vehicle;
transferring the item from the first vehicle to a storage location on the second rack;
transferring the item from the second rack to the second vehicle; and
transferring the item from the second vehicle to one of the storage locations on the third rack:
wherein the step of conveying a first vehicle comprises driving the first vehicle along a first track adjacent the first rack and a second track adjacent the second rack and the step of conveying a second vehicle comprises driving the second vehicle along a third track adjacent a second side of the second rack and a fourth track adjacent the third rack.

11. The method of claim 10 wherein the step of conveying a first vehicle comprises driving the first vehicle around a first loop formed of a first plurality of generally vertical tracks connected with a first plurality of generally horizontal tracks and the step of conveying a second vehicle comprises driving the second vehicle around a second loop formed of a second plurality of generally vertical tracks connected with a second plurality of generally horizontal tracks.

12. The method of claim 10 comprising the step of conveying the second vehicle and the item to a picking station positioned along the second aisle and presenting the item to an operator at the picking station.

13. The method of claim 10 wherein the item comprises a first storage container having a releasable connector and the method comprises the step of releasably connecting the first storage container with a second storage container located in the second rack.

14. The method of claim 13 comprising the step of displacing the first storage container in the rack by displacing the second storage container connected to the first storage container.

15. The method of claim 14 comprising the step of disconnecting the second storage container from the second storage container.

16. The method of claim 15 wherein the step of disconnecting comprises displacing the first container relative to the second container.

17. The method of claim 10 wherein the step of transferring the item from the first vehicle to a storage location on the second rack comprises the steps of:
aligning the first vehicle with the storage location on the second rack; and
operating a first transfer mechanism on the first vehicle to transfer the item to the storage location.

18. The method of claim 17 wherein the step of transferring the item from the storage location on the second rack comprises the steps of:
aligning the second vehicle with the storage location; and
operating a second transfer mechanism on the second vehicle to transfer the item to the second vehicle.

19. The method of claim 10 wherein:
the step of conveying a first vehicle through a first aisle comprises constraining the first vehicle to travel within the first aisle; and
the step of conveying a second vehicle through a second aisle comprises constraining the second vehicle to travel within the second aisle.

20. A method for operating an automated storage and retrieval system, comprising the steps of:
conveying a first vehicle through a first aisle between a first rack of

Assignees

• Opex Corp

Inventors

• Valinsky Joseph
• Dewitt Robert R
• Stevens Alexander
• Kumar Dhruva

Classifications

• B65G1/1375 Primary

  the orders being assembled on a commissioning stacker-crane or truck · CPC title

• B65G1/0492 Primary

  with cars adapted to travel in storage aisles · CPC title

• B65G1/0435

  with pulling or pushing means on either stacking crane or stacking area · CPC title

• B65G1/0421

  with control for stacker crane operations · CPC title

• B65G2201/0235

  Containers · CPC title