Transport rack cartridge (TRC)

Patent metadata

Field	Value
Publication number	US-12134518-B2
Application number	US-202117236082-A
Country	US
Kind code	B2
Filing date	Apr 21, 2021
Priority date	Apr 21, 2020
Publication date	Nov 5, 2024
Grant date	Nov 5, 2024

Abstract

A rack or racking system is disclosed for use in inventory management, order fulfillment and automation-based capacity planning. The racking system includes expandable and collapsible racks used to transport containers, for example, totes, which in the expanded configuration can attach to a load/unload fixture that enables bots to load totes onto the racks and/or unload totes from the racks, and in the collapsed configuration can be loaded onto a truck that transports the totes between facilities.

First claim

We claim:

1. A racking system configured to operate with an automatic storage and retrieval system (ASRS) having mobile robots transferring containers to and from storage locations in a storage structure, the racking system comprising:
a first tote support structure; and
a second tote support structure, the first and second tote support structures capable of moving with respect to each other between a first position where the first and second tote support structures are configured with an aisle between the first and second tote support structures and configured to receive containers from a mobile robot of the mobile robots from the ASRS travelling within the aisle, and a second position where the first and second tote support structures are compacted for transport;
wherein the racking system is configured to be shipped in the first position with totes stored in the first and/or second tote support structures and one or more mobile robots positioned within the aisle between the first and second tote support structures.

2. The racking system of claim 1 , further comprising a collapsing guide structure affixing the first and second tote support structures to each other.

3. The racking system of claim 2 , wherein the collapsing guide structure collapses as the first and second tote support structures move from their first position to their second position.

4. The racking system of claim 1 , wherein the racking system is configured to be shipped in the second, compacted position with totes stored in the first and/or second tote support structures.

5. The racking system of claim 1 , wherein the first and second tote support structures are configured to mount to a fixture enabling mobile robots to load totes onto the first and/or second tote support structures, and/or unload totes from the first and/or second tote support structures.

6. The racking system of claim 1 , further comprising a first plurality of storage shelves for storing totes in the first tote support structure and further comprising a second plurality of storage shelves for storing totes in the second tote support structure.

7. The racking system of claim 6 , wherein the first and second plurality of storage shelves are configured to store totes lengthwise or widthwise.

8. The racking system of claim 7 , wherein a footprint of the racking system when in the second compacted position is smaller when the totes are stored widthwise as compared to when the totes are stored lengthwise.

9. An automated storage and retrieval system (ASRS), comprising:
a first plurality of storage shelves arranged in an array of rows and columns;
a second plurality of storage shelves arranged in an array of rows and columns;
an aisle separating the first and second plurality of storage shelves, the first plurality of storage shelves, the second plurality of storage shelves and aisle together configured to allow a mobile robot to travel vertically and horizontally within the aisle to transfer containers to and from any of the first and second plurality of storage shelves;
a first section of the first plurality of storage shelves and a second section of the second plurality of storage shelves together being removable as a modular section, the modular section configured to move between a first position, where the first and second sections are spaced apart from each other and configured to receive the mobile robot therebetween, and a second position where the first and second sections are compacted toward each other for transport of the modular section away from the ASRS.

10. The ASRS of claim 9 , further comprising a collapsing guide structure affixing the first and second sections of the modular section to each other.

11. The ASRS of claim 10 , wherein the collapsing guide structure collapses as the first and second sections of the modular section move from their first position to their second position.

12. The ASRS of claim 9 , wherein the first and second sections of the modular section comprise a first set of guide rails that align with a second set of guide rails in a remainder of the first and second plurality of storage shelves not including the modular section, the first and second sets of guide rails enabling mobile robots to travel freely between the first and second sections and the remainder of the first and second plurality of storage shelves while the modular section is affixed as part of the first and second plurality of storage shelves.

13. The ASRS of claim 9 , a face of the modular section defining a plane, and wherein the modular section is configured to be removed widthwise, perpendicular to the plane.

14. The ASRS of claim 9 , a face of the modular section defining a plane, and wherein the modular section is configured to be removed lengthwise, parallel to the plane.

15. The ASRS of claim 9 , further comprising an automated motorized robot for removing the modular section from the ASRS.

16. An automated storage and retrieval system (ASRS), comprising:
a plurality of modular racks, each modular rack comprising:
a first tote support structure, and
a second tote support structure, the first and second tote support structures capable of moving with respect to each other between a first position where the first and second tote support structures are configured with an aisle between the first and second tote support structures and configured to receive containers from a mobile robot travelling horizontally within the aisle at one of multiple levels, and a second position where the first and second tote support structures are compacted for transport; and
a rack docking module configured to affix to an end of one or more of the plurality of modular racks, the rack docking module raising and lowering the mobile robot to travel at different levels of the multiple levels between the first and second support structures.

17. The ASRS of claim 16 , further comprising a dock interface structure configured to connect one or more of the plurality of modular racks to the rack docking module.

18. The ASRS of claim 17 , wherein the dock interface structure comprises blocking gates configured to move between a closed position where the blocking gates prevent passage of mobile robots between the one or more modular racks and the rack docking module, and an open position where the blocking gates allow passage of mobile robots between the one or more modular racks and the rack docking module.

19. The ASRS of claim 16 , wherein the rack docking module comprises a first rack docking module and the end of the one or more modular racks comprises a first end;
the ASRS further comprising a second rack docking module affixed to a second end of one or more of the plurality of modular racks opposite the first end, the first and second rack docking modules raising and lowering the mobile robot to travel at different levels of the multiple levels between the first and second support structures.

20. The ASRS of claim 16 , wherein the plurality of rack modules comprise two or more rack modules arranged lengthwise end to end.

21. The ASRS of claim 20 , further comprising a first set of rails in a first of the two or more rack modules and a second set of rails in a second of the two or more rack modules, the first and second sets of rails aligned with each other to allow passage of the mobile robot horizontally between the first and second rack modules.

22. The ASRS of claim 16 , wherein the plurality of rack modules comprise two or more rack modules arranged wid

Assignees

• Walmart Apollo Llc

Inventors

• Lert Jr John G
• Fosnight William J

Classifications

• B65G1/0492

  with cars adapted to travel in storage aisles · CPC title

• B65G1/10 Primary

  with relatively movable racks to facilitate insertion or removal of articles {(cabinets with means for moving compartments up and down A47B51/00; cabinet system, e.g. consisting of cabinets arranged in a row with means to open or close passages between adjacent cabinets A47B53/02)} · CPC title

• B65G1/1371

  with data records · CPC title

• B65G1/1378

  the orders being assembled on fixed commissioning areas remote from the storage areas · CPC title

• B65G1/1375 Primary

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